STREAMLINE HIGH-PRESSURE WATERJET PUMP

OPERATION and SERVICE MANUAL STREAMLINE SL-IV 50 STREAMLINE SL-IV 50 400 V / 3 / 50 Hz Manual No. 05146311 Rev. 3 Original: July 2003 CPN-Nr.: 80800-GB-08

NOTICE

This document contains subject matter in which KMT Waterjet Systems Company has proprietary rights. Recipients of this document shall not duplicate, use, or disclose information contained herein, in whole or in part, for other than the purpose for which this manual was provided.

KMT Waterjet Systems believes the information described in this manual to be accurate and reliable. Much care has been taken in its preparation, however, the Company cannot accept any responsibility, financial or otherwise, for any consequences arising out of the use of this material. The information contained herein is subject to change, and revisions may be issued to advise of such changes and/or additions.

KMT Waterjet Systems 2004

KMT Waterjet Systems Wasserstrahl-Schneidetechnik GmbH Auf der Laukert 11 D – 61231 Bad Nauheim, Germany Tel. +49 (0) 60 32 – 997 0 Fax: +49 (0) 60 32 – 997 270 E-Mail: [email protected]

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SECTION 0 TABLE OF CONTENTS

TABLE OF CONTENTS

1 INTRODUCTION (1) 1-1 1.1 Description 1-1 1.1.1 Features 1-3 1.2 Functional Description 1-3 1.2.1 Functional Features 1-3 1.3 Worldwide Product Support 1-5 1.3.1 GOLD- und SILVER-Service - Cost-Calculation Security 1-5 1.3.2 Service Department 1-5 1.3.3 Parts Support 1-6 1.3.4 Questionnaire 1-6 1.4 Safety 1-9 1.4.1 Labels and Abbreviations 1-9 1.4.2 Safety Procedures 1-11 1.4.3 High-Pressure (HP) Piping Safety 1-13 1.4.4 Emergency Medical Treatment 1-14

2 INSTALLATION (2) 2-1 2.1 Installation Overview 2-1 2.1.1 Buyer Obligations 2-1 2.1.2 Seller Obligations 2-1 2.2 Installation Requirements (Utilities) 2-2 2.2.1 Equipment Location/Environment 2-2 2.2.2 Service Connections 2-3 2.2.3 and Equipment 2-5 2.2.3.1 HP Tube Coning and Threading Procedures 2-5

3 OPERATION (3) 3-1

4 MAINTENANCE (4) 4-1 4.1 Scheduled Maintenance 4-3 4.2 General Maintenance 4-4

5 TROUBLESHOOTING (5) 5-1 5.1 TROUBLESHOOTING - Electrical 5-1 5.2 TROUBLESHOOTING – HP WATER 5-3 5.3 TROUBLESHOOTING – LP WATER 5-5 5.4 SPECIAL PROCEDURE—HP WATER CHECK VALVE TROUBLESHOOTING 5-6 5.4.1 HP Check Valve Troubleshooting 5-6 5.4.2 OUTLET HP Check Valve – Troubleshooting 5-6 5.4.3 INLET Water Check Valve – Troubleshooting 5-7

6 LOW PRESSURE WATER SYSTEM - FEATURES (6) 6-1 6.1 Oil Cooling Water Supply 6-1 6.2 Cutting Water Supply 6-1 6.2.1 Normal Operating Condition 6-2 6.2.2 Operation 6-2 6.2.3 Booster Pump 6-5

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6.2.4 Low Pressure System Protection 6-5 6.3 Maintenance Overview 6-6 6.3.1 Water Filter Service 6-6 6.3.2 Booster Pump 6-6

7 HIGH-PRESSURE (HP) WATER (7) 7-1 7.1 Components 7-1 7.2 Intensifier Disassembly and Reassembly 7-1 7.2.1 HP & LP Water Piping 7-3 7.2.2 HP Cylinder “Jug” (HP Cyl., Sealing Head, Flanges, & Studs)—Disassembly / Re- assembly 7-4 7.2.3 Stud Nuts and End Flange, Sealing Head—Disassembly / Re-assembly 7-5 7.2.4 HP Seal Service-- Disassembly / Re-assembly 7-7 7.2.5 Plunger and Hydraulic Cartridge Removal and Installation 7-11 7.2.6 Hydraulic Cylinder Head and Piston—Removal / Re-Installation 7-12 7.3 Intensifier Subassemblies Inspection and Repair 7-14 7.3.1 Discharge HP Check Valve 7-14 7.3.2 Inlet Check Valve 7-15 7.3.3 Sealing Head 7-16 7.3.4 HP Cylinder 7-17 7.3.5 Plunger 7-18 7.3.6 Hydraulic Piston 7-19 7.3.7 Hydraulic Cylinder 7-22 7.4 HP Dump Valve 7-23 7.5 HP Attenuator 7-23

8 ELECTRICAL SYSTEM - FEATURES (8) 8-1 8.1 Electrical Overview 8-1 8.1.1 Motor Starter Circuit 8-1 8.1.2 Control Circuits and Logic 8-1 8.1.3 Operation 8-3 8.2 Maintenance Overview 8-5 8.2.1 Proximity Switch Service 8-6 8.2.2 Optical Relay Switch Service 8-7

9 HYDRAULIC SYSTEM - FEATURES (9) 9-1 9.1.1 Components 9-2 9.2 Operation 9-2 9.2.1 Hydraulic Pressure Adjustment 9-3 9.2.2 Hydraulic System Pressure Protection 9-3 9.3 Motor / Hydraulic Service Maintenance 9-3 9.3.1 Motor Service 9-4 9.3.2 Manifold Service 9-4 9.3.3 Motor/ Pump Coupling – Spline Lubrication— 9-5

10 RECIRCULATION SYSTEM - FEATURES (10) 10-1 10.1 Components 10-1 10.2 Operation 10-1 10.3 System Pressure Protection 10-2

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10.4 Maintenance Overview 10-3

11 SPECIFICATIONS (11) 11-1 11.1 Equipment Specifications 11-1 11.2 Torque Specifications 11-3 11.3 Cutting Water Specifications 11-4

12 SPARE PARTS CATALOGUE (12) 12-1 12.1 General 12-2 12.2 Part Nomenclature 12-2

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SECTION 1 INTRODUCTION

Section 1 INTRODUCTION

1 Introduction (1)

The Streamline™ IV / PLUS (SL-IV / PLUS) waterjet pump maintains the level of component reliability and the ease of installation and maintenance that has made KMT Waterjet Streamline waterjet pumps the standard of the industry for both water and Hydrobrasive™ applications. The SL-IV / PLUS waterjet pump provides output water pressures up to 4,100 bar (60,000 psi) for ultrahigh-pressure waterjet cutting, hydrobrasive cutting, cleaning, surface preparation, etc. This manual provides information for installation, operation, and maintenance of the SL-IV / PLUS waterjet pump.

1.1 Description The SL-IV / PLUS waterjet pump is a self-contained functional unit. The major assemblies within the SL-IV / PLUS intensifier are single (or optional redundant) high-pressure intensification assemblies, single or dual high- pressure attenuator(s), a motor and hydraulic pump assembly, an oil cooling/filtration system, a low pressure water booster pump with low pressure water filtration, a fail-safe high-pressure venting valve, and an integrated NEMA 12 electrical control enclosure.

.jpg Letter Connection U Cutting Water OUT ...3/8” HP V Plant Air ...... ¼” NPT W Cooling Water IN...... ½” NPT X Cooling Water OUT ...½” NPT Y Cutting Water IN...... ½” NPT Z Drain...... ½” NPT 01/2004 1 - 1

SECTION 1 INTRODUCTION

NOTE KMT Waterjet Systems recommends approx. 950 mm / 36” minimum clearance around intensifier for maintenance.

Dimension Letter mm inch A 1.721 67,75 B 914 36,00 C 1.453 57,19 F 914 36,00 G 812 32,00 H 419 16,50 I 343 13,50 K 267 10,50 L 191 7,50 M 1.092 43,00 N 330 13,00

The SL-IV / PLUS waterjet pump is enclosed in a frame 67.75” (172 cm) long, 36.0” (91 cm) wide and 57.19” (145 cm) tall. The high-pressure intensification assembly is mounted on a drip pan on the frame top at a convenient height for performing routine maintenance. All components requiring routine maintenance are easily accessible through self-levitating hinged transparent covers or removable protective panels covering the sides of the lower frame. The high-pressure intensification assembly can be easily and quickly removed from the intensifier base if deemed desirable or necessary for maintenance.

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SECTION 1 INTRODUCTION

1.1.1 Features • Variable displacement, pressure compensated axial piston hydraulic pump. • Inlet water pressure booster pump and filtration system with 10-micron high capacity filter. • High efficiency oil-to-water heat exchanger and cartridge oil filter in an oil circulation pump circuit separate from the main hydraulic pump circuit. • Thermostatically controlled water-cooling system for optimum hydraulic oil temperature stability. • Integrated electrical controls include a standard wye-delta motor starter to minimize motor inrush current at startup. • High-pressure safety dump valve. • Dual pressure compensators on the main hydraulic pump allow manual or program controlled selection of two different output pressures. • Optional electronically controlled continuously variable hydraulic pressure control may be integrated into the host CNC unit for real-time pressure control. • TUV approved high-pressure attenuator for smooth high-pressure water delivery. • TUV approved pre-set hydraulic relief valve eliminates the need for rupture disc overpressure protection. • Microprocessor control with diagnostic capability and multi-language touch screen operator interface. • Cutting water solenoid-operated shutoff valve. • Inlet water pressure and booster pressure switches insure that there is adequate supply water pressure to the SL-IV / PLUS high-pressure intensification assembly to prevent water starvation damage. • Separate water and oil drip pans for cleanliness. • Remote control electrical interface connector port. • Remote diagnostic communication option.

1.2 Functional Description

The HP intensification assembly uses a hydraulically driven piston operating in electrically reversed reciprocating mode, coupled at both ends to high-pressure intensification cylinders. The HP intensification cylinders extrude high-pressure water alternately, while the HP attenuator minimizes fluctuations in the output water signal. The intensification ratio is 20:1 with maximum hydraulic pressure set at 3,100 psi.

1.2.1 Functional Features

• 4,150 bar (60,000 psi) operating pressure • Electronic reversing 01/2004 1 - 3

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• 24vdc control logic • Built-in high-pressure water leak detection diagnostics • Standard dual pressure control facilitates hole piercing and kiss cut applications • Exclusive long, slow plunger stroke • Cartridge type hydraulic seals • Low pressure water booster pump and filtration • Reduced cooling water requirements • Choice of English, German, Spanish, French, Swedish and Italian readouts as standard • Meets CE requirements

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1.3 Worldwide Product Support

The KMT Waterjet Service Department serves the customer, by providing: Supervision of equipment installation, start up, and training for the number of days specified in the quotation, and per approved project. Additional time requested will be invoiced on a per diem basis, plus travel and normal living expenses. Field Services: on-site technical support is available on request. These services are invoiced on a per diem basis, plus travel, and normal living expenses. Technical Assistance: the Service Department is available for technical assistance by phone. Training: the Service Department conducts periodic training sessions at KMT Waterjet designated training locations. On-site training is also available.

1.3.1 GOLD- und SILVER-Service - Cost-Calculation Security The economics of an investment in a waterjet cutting machine, is not only a top priority for start up companies. The purchase price of a machine was and always will continue to be an important consideration, the running costs however, have been rather difficult to estimate. The goal of our Gold- & Silver- Service is exactly the correction of this situation: The concept consists of a fixed per hour paid by the enduser of the KMT Waterjet high pressure and cutting equipment. The application type (pure water or ) as well as the local installation-conditions at the customer site give us the cornerstones necessary for the construction of such a package. Within this offering, the customer has the option of deciding whether the maintenance and service activities are to be carried out by his own personnel (Silver-Service) or if KMT Waterjet service technicians are to perform all of these actions (Gold-Service). Both packages include scheduled visits of KMT Waterjet Technicians, as well as any possible additional training required by the responsible maintenance personnel. This is how KMT Waterjet allows customers new to waterjet cutting to be fully prepared for all the possible technical questions down to the smallest detail. Questions get answered in direct dialog with our service technician, allowing for cost- conscious operation. For companies not interested in having to maintain their own equipment. The additional advantage of this lies in the fact that KMT Waterjet is able to offer Gold and Silver Service, not only for new units, but also for pumps, already in the field.

1.3.2 Service Department The KMT Waterjet Customer Service group provides parts and service support. On-Site Service Support • Equipment installation and start-up supervision. • Equipment relocation supervision. • Equipment performance assessment. • Remedial maintenance supervision. • Preventive maintenance supervision. • Maintenance training. Phone Service Support:

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Service personnel available for technical phone assistance during and after work hours.

Scheduled Maintenance training Periodic Periodic training sessions are conducted at KMT Waterjet designated training locations. Call the Waterjet Service Manager for schedule information.

1.3.3 Parts Support KMT Waterjet maintains a comprehensive parts department staffed by trained, expert personnel. Same-day shipment is routine, and emergency shipment is available upon request.

To contact the KMT Waterjet Service Department:

USA: Service Manager Europe: Technical Manager KMT Waterjet Systems KMT Waterjet Systems 635 West 12th Street Auf der Laukert 11 Baxter Springs, KS 66713 D–61231 Bad Nauheim USA Germany Phone: (620) 856–2151 Phone: + 49–(0)6032–997–117 Fax: (620) 856–5050 Fax: +49–(0)6032–997–270 E-Mail: [email protected]

1.3.4 Questionnaire The following equipment and service manual questionnaire will provide information to allow us to serve you better. Please complete them at your convenience and return to the applicable Service Department as shown above.

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EQUIPMENT AND SERVICE MANUAL QUESTIONNAIRE

A new SL-IV / PLUS waterjet pump has been installed at your location. We are interested in your initial impressions of the unit and its installation. Please take a few moments and answer the following questions.

General Appearance Was unit received in good condition? Yes No

Comments: ______ Yes No Is the unit a convenient size? 1. Controls a. Are the controls user friendly? Yes No

b. Is the unit easy to operate? Yes No

Comments:

2. Performance a. Does the unit perform smoothly and meet your Yes No expectations? Yes No b. Does the unit run quietly?

Comments:

3. Did installation and start-up go smoothly? Yes No

Comments:

4. What feature(s) do you consider the most significant with this unit? Quiet Operation Appearance Performance (Operation) Repair/Maintenance

Other 5. What areas need improvement? Appearance Servicability Performance ______

Other

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Manual Organization

1. Does the table of contents help you find topics easily? Yes No

Comments:

2. Is the information well organized? Yes No

Comments:

3. Is the page layout suitable for the material being Yes No presented?

Comments:

Graphics

How do you rate the quality and quantity of the Yes No photos/illustrations?

Comments:

Text

1. Does the information in the manual adequately explain how Yes No to operate and service the equipment?

Comments:

2. Are there paragraphs or procedures you feel need Yes No clarification? Please identify them by page number and add your comments.

Comments:

3. Is there anything you would add or delete from the manual Yes No to make it more useful?

Comments:

4. Is there any information that should receive more Yes No emphasis?

Comments:

Name: Title:

Company

Address:

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SECTION 1 INTRODUCTION

1.4 Safety

Safety procedures and safe practices must be followed during installation, operation, and maintenance of the waterjet pump. In this section we have provided label and sign descriptions used in this manual, as well as recommended safety procedures.

1.4.1 Labels and Abbreviations The following describes hazard classifications of the waterjet pump.

Indicates the presence of a hazard that can cause CAUTION personal injury, or property damage if the caution

instruction is ignored. Indicates the presence of a hazard that can cause severe WARNING personal injury, death, or substantial property damage

if the warning instruction is ignored. High pressure waterjet can cause eye injury. Wear eye protection when operating or working near machine. Hazardous noise can cause hearing loss. Wear ear protection when operating or working near machine. Hazardous voltage within can cause injury or death. Disconnect and lockout main power before opening cabinet. ! Malfunction

Hydraulic Intensifiers

Pressure Control

High Pressure

Low Pressure

Start/Control Power On

Stop

Run

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SECTION 1 INTRODUCTION

Rear of Waterjet Pump

Item Symbol Connection

1 HP Water "OUT" ...... 3/8” HP

2 Plant Air "IN"...... ¼” NPT

3 Cooling Water "IN"...... ½” NPT

4 Cooling Water "OUT" ...... ½” NPT

5 Cutting Water "IN"...... ½” NPT

6 Drain ...... ½” NPT

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Figure 1-1 shows other safety labels or icons used on the SL-IV / PLUS waterjet pump. Pressure warning (Figure 1-1(a)) warns against the hazard of trapped HP water or hydraulic pressure after the pump has been shut off. All high- pressure can be safely bled off if the operator will leave the HP cutting water valve open for a few seconds after shutting off the pump.

Figure 1-1(b) warns of electrical shock hazard when in the vicinity of the electrical enclosure or motor junction . Figure 1-1(c) warns of hot surfaces on the HP water and hydraulic components while the pump is in normal operation.

WARNING

Pumping System can remain pressurized when pump is not operating. Can cause injury or death. Disconnect pump power source and depressurize system before servicing

Figure 1-1. Other Safety Labels & Icons Used on the SL-IV Waterjet Pump (a) Trapped HP Water or (b) Electrical Shock Hazard (c) Hot Surface Warning Hydraulic Oil

1.4.2 Safety Procedures Safety procedures must be observed while working on the pump, or any high- pressure component. Service should only be performed by trained, qualified personnel. • The high-pressure water, 4,100 bar (60,000 psi) resident in a waterjet cutting system is an extremely high-energy medium. Persons working in the vicinity of high-pressure must exercise due respect for this pressure and always observe proper SAFETY PROCEDURES and SAFE WORK HABITS. • Everyone associated with the waterjet cutting system must realize that the force of the waterjet cutting stream can penetrate many dense and strong materials. • Keep all untrained people away from the waterjet cutting area. Use barriers or partitions if needed. • Safety must be worn at all times in the waterjet cutting area.

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• All EMERGENCY STOP buttons must be checked periodically. The normal operating position is pulled out. • To check: turn on power and activate the EMERGENCY STOP buttons one- at-a-time by pushing them in to insure that each button will shut the system down. Reset the pushbutton by pulling it out until it clicks. Each device should be checked on a specified schedule. Each time the device is checked, it must function or be replaced before operating the system. • Apply High Purity Goop (P/N 49864887) to all threaded high-pressure connections. All tubing, fittings and bolted connections should be torqued to recommended values. Do NOT attempt to tighten or loosen a HP water fitting when the circuit is pressurized, see High-Pressure (HP) Piping Safety. • All high-pressure leaks must be repaired immediately. • Inspect all equipment on a scheduled basis. • Before performing any maintenance on the unit, MECHANICALLY LOCK THE MAIN CONTROL POWER OFF, and assure that all high-pressure has been bled off.

Never do any work on the unit without making sure the WARNING electrical panel disconnect is locked out with a padlock in the OFF position, and that the proper tagout procedure has been implemented.

Never work on any high-pressure component, or loosen WARNING any high-pressure fitting without first bleeding the system and assuring there is no high-pressure water present.

Make sure the safety devices are operational. To panic WARNING stop the pump and bleed the high-pressure, an EMERGENCY STOP button must be pushed in while the system is active. The intensifier high-pressure dump valve will automatically open to bleed off the stored pressure.

Do not attempt to touch the waterjet stream, or contact WARNING the high-pressure water. The high-pressure water will

penetrate all parts of human body without exception.

WARNING The liquid stream or material ejected by these extreme pressures can injure or kill.

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SECTION 1 INTRODUCTION

1.4.3 High-Pressure (HP) Piping Safety High-pressure piping must be installed without torsional or bending stresses. Proper supports and guides must be provided. 9/16” outside diameter HP tubing and fittings are recommended between the pump and the cutting station. This large tubing size will reduce vibration, strain and motion between the pump piping and the cutting area. The large piping diameter also reduces dynamic pressure drop and pressure pulsation.

Do not try to repair a leak in a HP water fitting when it is pressurized. Always shut off the power and bleed the HP water before doing maintenance on HP components. WARNING Weep holes are provided to release HP water if leakage occurs at a sealing surface. If a fitting is loosened with HP water present, a jet of HP water will exit the nearest weep hole with possible hazardous results.

Use extreme caution when handling high-pressure equipment. Possible failure from fatigue cracking or WARNING over-pressurization can result in a hazardous high-

pressure leak, or component failure.

A flexible ¼” HP tube (whip) is frequently used on the

cutting system to allow cutting nozzle movement. WARNING Supports and guides for the whip must be used, anti- vibration fittings and proper support must be provided to prevent failures from external loads (non-water related stresses). The whip will only flex in a single without being subjected to torsional stress. Torsional flexing will precipitate tubing failure. To prevent torsional stress, the use of high-pressure swivels is strongly recommended. To prolong swivel life the whip must pass through rigid support bearing blocks to prevent side-loading of the swivel .

When tightening or loosening HP connections, always WARNING use a supporting wrench to avoid bending forces or stress on the connection. Do not exceed recommended torque values

High-pressure piping and fittings designed to 4,100 bar (60,000 psi) must always be used. Failure to do so may WARNING lead to catastrophic component failure, which can cause equipment damage, injury or even death.

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SECTION 1 INTRODUCTION

1.4.4 Emergency Medical Treatment In order to aid treating a waterjet injury the below listed informations are to be forwarded to the doctor before starting any action. Medical Alert

“This person has been working with water jetting at pressures to 55,000 psi (374MPa, 3740 bar, 3867 Kg/cm2) with a jet velocity of 3,000 fps (914 mps). Foreign material () may have been injected with water. Unusual infections with microaerophilic organisms occurring at lower temperatures have been reported, such as gram negative pathogens as are found in sewage. Bacterial swabs and blood cultures may therefore be helpful. This injury must be treated as an acute surgical emergency and be evaluated by a qualified surgeon. Circulation may be compromised, therefore, DO NOT APPLY HEAT TO INJURED PART. For first aid: (1) Elevate injured part (2) Antibiotics (3) Keep injured person NPO.”

1_EJ5321-05130661_020311.doc

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SECTION 2 EQUIPMENT INSTALLATION

Section 2 EQUIPMENT INSTALLATION

2 Installation (2)

The installation, start-up, operation, and maintenance of the SL-IV / PLUS waterjet pump requires complete reading and study of this manual to understand the system in detail.

2.1 Installation Overview

Read the manual and become familiar with the operation of each component and its nomenclature. Understand the complete system and its function before operating it. Safety procedures and safe practices must be followed during installation, operation, and maintenance of the SL-IV / PLUS waterjet pump..

2.1.1 Buyer Obligations Equipment installation requires cooperation between the user and KMT Waterjet. If on-site support is requested, the KMT Waterjet Service Department will require the following tasks be accomplished before arrival at the customer site:

• The waterjet cutting equipment should be uncrated, positioned and leveled, with electrical and fluid services brought to the unit. • Provide and install power drops with fused disconnects sized to the equipment power requirements. • Provide and install pneumatic drops with manual shutoff valves. • Provide all mounting and support brackets and hardware for high-pressure tubing runs. • Provide and install water conditioning equipment necessary to meet water purity requirements. Provide and install manual shutoff valves. • Provide and install necessary cooling water inlet/outlet, and drain water connections to the intensifier pump, and/or cutting equipment and manual shut-off valves. • Provide suitably located and sized drains and proper disposal of waste water. • Provide, install and connect wiring between the intensifier pump(s), and the cutting station control system. • KMT Waterjet Systems supplies a pre-filled hydraulic system. If fluid is low or empty due to leakage during transit, the system must be filled per specifications.

2.1.2 Seller Obligations If KMT Waterjet Systems Service is requested, the following tasks will be the responsibility of the KMT Waterjet Systems technician at installation.

• Insure site preparation is satisfactory. • Remove internal strapping and blocking material.

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• Insure that power is connected prior to equipment turn on. • Insure that connections have been made for water and pneumatic service. • Test motor rotation direction and correct if necessary. • Check and test electrical signal connections between intensifier pump and cutting area. • Power up and check out pump (and cutting station, if supplied by KMT Waterjet Systems) for proper operation. • Install and test high-pressure . • Follow the standard test procedure to insure satisfactory performance. • Train maintenance personnel in the performance of maintenance and repair procedures. • Sign off the installation and testing on KMT Waterjet's standard acceptance document.

2.2 Installation Requirements (Utilities)

Environment: The SL-IV / PLUS waterjet pump must be installed indoors. Ambient conditions must not exceed maximum specifications. Moving: The SL-IV / PLUS waterjet pump has provisions to be moved with a forklift. Check weight specifications.

CAUTION The waterjet pump is top heavy. Avoid situations that could result in the equipment tipping or overturning.

Electrical connections must be made by qualified WARNING personnel, and must meet national and local electrical

codes.

2.2.1 Equipment Location/Environment Space Requirements: There should be a minimum of 900mm (36 inches) clearance on all sides of the pump to facilitate service.

Electrical Wiring: Insure that the service voltage and ampacity are proper for this SL-IV / PLUS pump. Voltage fluctuations in excess of +/- ten percent of nominal voltage may damage the SL-IV / PLUS Pump and will void the warranty. Refer to Section 11, “Specifications”.

Control Wiring: Wiring for remote control of the pump must be in accordance with national and local electrical codes. The SL-IV / PLUS Waterjet Pump has a 24vdc electrical control system and has a connector port for remote operation wiring on the pump control enclosure. 01/2004 2 - 2

SECTION 2 EQUIPMENT INSTALLATION

2.2.2 Service Connections

Cooling Water IN/OUT: Supply plumbing must be properly sized to handle the necessary flow and pressure. Piping must meet national and local piping codes. If municipal or well water is used for cooling, insure that the supply will flow a minimum of 3 gallons per minute at a minimum of 30 PSIG under maximum usage conditions. If a facility-wide chilled water (active or evaporative tower) system is used for cooling, insure that there is a minimum of 30 PSIG pressure differential between the facility supply and the return (discharge) plumbing. Installation of an in-line pressure boosting pump may be necessary to provide adequate cooling flow.

Cutting Water IN: Supply piping must be properly sized to handle the necessary flow and pressure, and must be capable of providing a minimum of 30 psi at maximum flow demand to insure adequate supply to the intensifier. Piping must meet national and local piping codes. Prior to operation, insure that the cutting water meets minimum standards listed in Section 11 “Specifications”. Operation without proper water quality will shorten the life of certain intensifier parts and void their warranty. Use only plastic or copper plumbing from the cutting water source to the SL-IV / PLUS pump cutting water supply filter. Thoroughly purge the cutting water supply plumbing prior to connecting to the SL-IV / PLUS pump to avoid construction residue contaminating the pump.

HP Water OUT: Properly rated, sized, and supported high pressure (HP) piping must be used to transport the high-pressure water from the SL-IV / PLUS pump to the point of use. If new HP discharge piping is installed, all burrs that might come loose under high pressure must be carefully removed, and the tubing sections purged with compressed air prior to assembly. Further, it is strongly recommended that the HP piping be purged under high pressure operating conditions, using a large, cheap orifice. Contamination from the HP piping will be released when the tubing expands under pressure. If the HP piping is not purged, expect to have early HP valve and orifice failures. All parts should have High Purity Goop (P/N 49864887) applied to the threads and contact surfaces prior to assembly. Do NOT USE ANY OTHER ANTI-SEIZE COMPOUND. Failure to use High Purity Goop will result in galling of the parts, and will generally render them unusable. Do not use High Purity Goop on ANYTHING but stainless steel!

Drain: Cutting water released in the activation of EMERGENCY STOP will be discharged from the intensifier drain port and must be piped to an appropriate location (i.e. sewer line). The volume of water released will be minimal, and will not require high-pressure plumbing. Piping must meet national and local piping codes.

Compressed Air: The facility air connection to the SL-IV Pump should provide clean, dry air at 5,9 bar [85 PSIG]. Air usage is minimal and less than 1 SCFM. 01/2004 2 - 3

SECTION 2 EQUIPMENT INSTALLATION

Item Symbol Connection

1 HP Water "OUT" ...... 3/8” HP

2 Plant Air "IN"...... ¼” NPT

3 Cooling Water "IN"...... ½” NPT

4 Cooling Water "OUT" ...... ½” NPT

5 Cutting Water "IN"...... ½” NPT

6 Drain ...... ½” NPT

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SECTION 2 EQUIPMENT INSTALLATION

2.2.3 Tools and Equipment

2.2.3.1 HP Tube Coning and Threading Procedures Determine Tube Length - Measure, the distance (L), between the fittings, then add two times the tube engagement length in the following table. Cut tubing to length and deburr.

High-pressure piping and fittings rated for 4,138 bar WARNING (60,000 psi) must be used. Failure to do so may result in component failure causing equipment damage, personal injury, or death.

Tube Engagement Length HP Tube Diameter Engagement (inch) Length (EL) mm (inch) 1/4" 12.7 (0.50) 3/8" 17.5 (0.69) 9/16" 21.3 (0.84)

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SECTION 2 EQUIPMENT INSTALLATION

Cone and Thread Tube Cone and thread both ends of the tube per following diagram and procedure.

Cone and Thread Dimensions O.D. Size I.D. size D (max) L (max) Thread mm (inch) mm (inch) mm (inch) mm (inch) NF-LH 6.35 (1/4") 2.11 (0.083) 3.58 (0.141) 14.3 (0.562) (1/4"- 28) 9.52 (3/8") 3.18 (0.125) 5.56 (0.219) 19.1 (0.750) (3/8"- 24) 14.27 (9/16") 4.78 (0.188) 7.14 (0.281) 23.8 (0.938) (9/16"- 18)

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SECTION 2 EQUIPMENT INSTALLATION

Cone and Threading

To cone the tubing, use the following figure as reference.

Item Description (1) Cutter Handle (2) Cutter Support (3) Feed (4) Cutting (5) (6) Housing (7) Gland Nut

Tube Size (inch) 1/4” 3/8” 9/16” A mm (inch) 3.30 (0.13) 4.07 (0.16) 7.11 (0.28) Coning Tool (IR Part) 10079556 10097418 10079663 Threading Tool (IR Part) 10079697 10097434 10097442

01/2004 2 - 7

SECTION 2 EQUIPMENT INSTALLATION

Coning • Place the appropriate size coning tool in a so that lubricant can flow to cutting blades (4). • Set feed nut (3) location as shown in dimension A. • Slide tubing through collet (5) until end contacts cutting blades (4) and tighten gland nut (7) just enough to firmly grip tubing. • Turn feed nut (3) counterclockwise to back cutters away from tubing, and tighten gland nut (7) with wrench. • Apply cutting oil through the opening in the coning tool. A medium weight cutting oil having high sulfur content is recommended. Use cutting oil freely throughout the cutting operation to prevent dulling the coning . • Turn feed nut (3) clockwise until cutting blades (4) contact end of tubing. • Rotate cutter handle (1) in clockwise direction while simultaneously the feed nut (3) in a clockwise direction at a rate to assure that the cutting blades (4) are taking a light cut at all times. • Continue rotating cutter handle until feed nut bottoms on housing (6), then rotate cutter handle several more revolutions to face-off the end of the cone. • Unscrew the feed nut (3), and remove the blade spindle (2) from the coning tool. Loosen the collet, slide the tubing (8) into the housing (6) until it extends approximately 100mm (4 inches) and then retighten the collet. Threading Place the appropriate sized threading tool on the coned end of the tubing, large end forward. Apply pressure to start the cutting action and rotate the holder counterclockwise until the threads are cut per the cone and thread dimension table.

01/2004 2 - 8

SECTION 2 EQUIPMENT INSTALLATION

HP Tube End Connection - Regular The following type of connection is for general applications, where the only load on tubing is due to internal pressure.

1. Slip the gland nut (2) on the tubing (1) as shown and lubricate the threads with a light coat of High Purity Goop. Thread the collar (3) on the tubing until one to two threads are exposed between the collar (3) and the tube cone. 2. Lubricate the male threads of the gland nut with High Purity Goop. Insert the tubing assembly into the fitting, engage the gland nut and tighten finger- tight. 3. Tighten the gland nut to the specified torque given in the torque table.

01/2004 2 - 9

SECTION 2 EQUIPMENT INSTALLATION

HP Tube End Connection - Antivibration The following type of connection must be used when tubing will be subjected to vibration, rotation, movement, and side loads (i.e. whip tubing). Lubricate threads as above. Do not depend on end connection to take the tubing WARNING load alone. Proper piping support and guide must be

provided.

WARNING Do not subject the tubing to torsional (rotational) stress. To do so will cause premature failure.

1. Slip the gland nut (2) and the anti-vibration collet (4) on the tubing (1). Thread the collar (3) on the tube until one to two threads are exposed between the collar and the tube cone. 2. Lubricate the male threads of the gland nut with High Purity Goop. Insert the tubing assembly into the fitting, engage the gland nut and finger tighten. 3. Tighten the gland nut to the specified torque according to the table of Recommended Torque Values in this section.

2_EJ5231-05130661_020312.doc

01/2004 2 - 10

SECTION 3 OPERATION

Section 3 OPERATION

3 OPERATION (3)

This section is devoted to an explanation of the SL-IV / PLUS control logic and operators interaction with it. The SL-IV / PLUS now has new, comprehensive fault detection and troubleshooting logic in the control, and allows operator control of the sensitivity of the overstroke detection in order to optimize the logic for specific operating conditions. The operator functions and warnings programmed in the control of this intensifier offers an unprecedented and comprehensive view of the operating parameters, impending faults, shutdown faults, and suggested remedies. The operator’s interface is now through a touch sensitive control display on the control console where several menu screens can be selected for various purposes. The screens and their use are explained in this section. The pages following will explain the functions available in the control, how to select them and use them to your advantage. The SL-IV / PLUS Waterjet Pump is composed of the following systems:

Following is an explanation of the functions of the new control logic, including the revised start-up sequence.

• The intensifier is now equipped with a booster pump output pressure switch. Seven seconds after the intensifier is started, the switch is monitored. If the switch opens, a warning is issued (message and flashing red light). If the condition persists for 30 consecutive seconds, the intensifier is shut down. • The intensifier is now equipped with an inlet cutting water pressure switch. If the switch is not closed, the intensifier will not start and a warning is issued (message and red flashing light). After the intensifier is started, if the switch opens, the same warning is issued. If the condition persists for 20 consecutive seconds, the intensifier is shut down. • The intensifier is now equipped with separate total hour and maintenance hour meters for topworks (T/W) one and (T/W) two. The operator can reset both maintenance meters. Both total meters can be set to any value via a password protected configuration screen. Without access to this screen, the hour meters will not be reset or changed. • The intensifier is now equipped with a maintenance function to allow the user to set the plunger in either the left or right position for ease of maintenance. • Overstroke (no longer called Leak) shutdown level is adjustable between 30% and 120% of full capacity. The overstroke warning level is automatically set 10% below the shutdown level set by the operator. Overstroke warnings, pending shutdowns and shutdowns are issued in three types, left, right and T/W. A T/W warning or shutdown indicates that the topworks is shifting too fast in both directions and would point more towards a problem with the orifice or plumbing rather than check valves or seals. If a left or right shutdown occurs, the display tells the operator which parts are suspect. Sometimes, especially if the intensifier is running near full capacity to begin with, a T/W shutdown can be displayed when it is actually caused by a left or right fault. This can be diagnosed further by turning the operating pressure down and watching the Alarms screen, which displays all alarm occurrences.

01/2004 3 - 1

SECTION 3 OPERATION

• Real-time running capacity and stroke rate are shown on the display. • A resettable stroke counter for both T/W one and T/W two are provided on the display. • The part numbers for both the plc and display logic along with revision number running on the machine are shown on the Maintenance Screen. • The plc now monitors the motor overload relay and displays a message when the overloads trip. The overloads will now be set on automatic reset rather than manual so the enclosure does not have to be opened to reset them. • The display will give a message (motor feedback failure) if the motor output goes high and the motor does not start or if the motor is running and the motor output is not high. • The start-up sequence will now be different depending on the circumstances. 1. Standard machine, start-up after machine has been E-stopped: Safety dump valve will be open. It will close 3 seconds after the T/W begins stroking. The pump will be held in low pressure for 20 seconds after motor is started after which pressure will go to high if high is selected, otherwise will stay in low. The purpose for this is to allow entrapped air to be bled from any HP cylinder that has been maintained to avoid hot air burning the plunger seals. 2. Standard machine, start up after normal stop: Safety dump valve will be closed, pump will be held in low pressure for 20 seconds after motor is started, after which the pressure will go to high if high is selected, otherwise will stay in low. The purpose for this is to allow entrapped air to be bled from any HP cylinder that has been maintained to avoid hot air burning the plunger seals. 3. Machine equipped with hp transducer, start up after E-stop: same as (1) above. 4. Machine equipped with hp transducer, start up after normal stop: If pressure is allowed to bleed through orifice to below 1000 psi, dump valve will open and start up will be like (1) above, if pressure is not allowed to bleed, start up will be as (2) above. • The display screen will always default to the Run screen after being on any other screen more than 5 minutes. • If the intensifier is equipped with a hp transducer, the displayed pressure can be shown in PSI or Bar. Recalibration of the transducer is automatic and does not require operator input. • If the intensifier is equipped with a hp transducer, another level of overstroke protection is obtained by shutting down at the warning level if the pressure is less than 3000 psi. • The display saves the last 100 shutdown messages, which can be viewed with times, dates and message contents.

01/2004 3 - 2

SECTION 3 OPERATION

MAIN MENUE

MAIN MENU RUN PRESS CONTROL SET-UP % CAPACITY HOURS ALARMS ALARM HISTORY CONFIGURATION MAINTENANCE LANGUAGES WATERJET

MAIN MENU Scroll up and down to page through the various screens and press ENTER to select desired screen.

RUN SCREEN (2) Start, Stop, Recirc, High/Low pressure, alarm indication. Select PSI/BAR.

PRESSURE CONTROL (2) Increment or decrement pressure setting – used only on machines equipped with analog pressure control.

SET-UP (2) Displays PLC and Display logic part and revision number, water reset function, and idle shutdown function. With analog control installed, screen includes Transducer and Proportional Select buttons.

PERCENT CAPACITY Set capacity, stroke count, select T/W 1 or 2.

HOUR METERS Display total operating hours for TW 1 and 2, resettable maintenance hours.

ALARMS Displays current alarms.

ALARM HISTORY Displays time and date of alarms and keeps history of 100 past alarms.

CONFIGURATION Secure screen used by manufacturer only.

MAINTENANCE Jog left, Jog right, start recirc, stop.

LANGUAGE Select Language.

01/2004 3 - 3

SECTION 3 OPERATION

RUN SCREEN THIS IS THE ONLY SCREEN WITH A MACHINE START FUNCTION

RUN SCREEN

PRESSURE*

* 4100

PRESSURE

RESET

LOW BOOSTER ALARM RECIRC PRESSURE

* In case no analog (pressure transducer or proportional valve) is installed on the machine, the display will not indicate any datas related to the operating pressure or pressure unit. Ref. Symbol Description

START “I” On all screens this indicates start or on

STOP “O” On all screens this indicates stop or off

Pressure Pressure Indicates machine output pressure, either in Bar or PSI #####

BAR/PSI The BAR/PSI button toggles the display for Bar or PSI

Return Returns to Main Menu In alarm state, the last alarm sensed by machine will ALARM ALARM be displayed. Multiple alarms can be displayed on the alarm screen.

Start Bar Will flash when the machine can be started

Will flash when the machine is running. The machine Stop Bar can be stopped with this button

01/2004 3 - 4

SECTION 3 OPERATION

RUN SCREEN

PRESSURE

4100

PRESSURE

RESET

LOW BOOSTER ALARM RECIRC PRESSURE

Ref. Symbol Description Select this to toggle the recirculation mode on or off. The recirc mode runs the machine without generating high pressure, and is used to circulate the hydraulic oil through the heat exchanger to cool the oil following a Recirc high temperature shutdown. RECIRC (I) indicates recirc on O (O) Indicates recirc is off Stop Recirc with STOP button

High-Low Select high or low water pressure. (Machine always Pressure starts in low pressure.) Arrow indicates selected Switch PRESSURE pressure following machine startup delay expiration

Indicates inlet water function must be reset. Reset by RESET RESET pressing STOP button

Run Screen ALARMS 1. High Oil temperature – Indicates high hydraulic oil temperature. 2. High Pressure Warning – Indicates that output pressure is above 64000 PSI or 4413 BAR. 3. Booster Temperature High – Indicates booster pump water temperature is high and machine shutdown is pending. 4. Low Booster Pressure – Indicates that booster pump output pressure is inadequate for proper machine operation and shutdown is pending. 5. Low Inlet Water Pressure – indicates that cutting supply water pressure is inadequate to permit proper machine operation and shutdown is pending. 6. Bleed High Pressure Lines – Indicates that the intensifier is shut down and that high pressure is present in the discharge plumbing of the intensifier that should be bled off to avoid the possibility of injury. 01/2004 3 - 5

SECTION 3 OPERATION

7. Left/Right/TW Overstroke Warning and Shutdown Pending – Indicates an abnormal high stroke rate caused by an external or internal leak. If the condition persists, the machine will be shut down with an Overstroke Shutdown alarm.

HOURS

HOURS INT 1 TOTAL HOURS RESET INT 19999999.9 MAINT HOURS INT 29999999.9 INT 2

MAINTENANCE RESET HOURS MAINT INT 1 9999999.9 HOURS INT 2 9999999.9

Machine can be Stopped from this screen.

Ref. Symbol Description HOURS TOTAL HOURS This screen displays total machine hours*... MAINTENANCE ... and resettable maintenance hours to

HOURS 9,999,999 for intensifiers 1 and 2

Flashing bar indicates that the machine is on

TOTAL HOURS ... cannot be reset ... on intensifiers 1 and 2 can be reset by MAINTENANCE pressing the RESET MAINT HOURS display HOURS button Return Returns to Main Menu

01/2004 3 - 6

SECTION 3 OPERATION

ALARM HISTORY SCREEN

ALARMS-DATE/TIME

- MM/DD/YY 2H:MM:SS BOOSTER TEMP HIGH

(EXAMPLE) Ref. Symbol Description The alarm list stores the last 100 triggered alarms

indicating date, time and type of alarm

Scroll up and down to see alarm history

Return Returns to Main Menu

The Alarm History Screen does not have an intensifier STOP function.

01/2004 3 - 7

SECTION 3 OPERATION

PRESSURE CONTROL SCREEN

PRESSURE CONTROL

PRESSURE 4100

Ref. Symbol Description

Set pressure to desired setting from 0 to 100 % SET in 1 % increments. RIGHT arrow to increase PRESSURE pressure, LEFT arrow to decrease pressure

HIGH/LOW pressure switch and UP/DOWN HIGH/LOW arrow indicating high or low pressure also on PRESSURE PRESSURE this screen. The same function is on the RUN screen or

... is also indicated on this screen in either PSI or BAR. Can be changed on PSI/BAR SELECT Machine PRESSURE button. Same function is on the RUN screen. PRESSURE 4100 This function is only found on machines with a transducer installed

Return Returns to Main Menu PRESSURE CONTROL SCREENS will not appear if analog module (pressure transducer and/or proportional valve) is not installed on the machine. If pressure control on main menu is selected and a proportional valve is not installed, a screen will appear indicating “THIS UNIT IS NOT EQUIPPED WITH PROPORTIONAL CONTROL”.

01/2004 3 - 8

SECTION 3 OPERATION

The PRESSURE CONTROL SCREEN that is required can be selected on the SET- UP SCREEN for the appropriate pressure control. Used if a proportional valve, a pressure transducer, or both are used on machine. These are the TRANSDUCER SELECT and PROPORTIONAL SELECT buttons on the SET-UP SCREEN.

PERCENT CAPACITY SCREEN

STROKE INT 1 ####### COUNT INT 2 #######

SHUT STROKES/MIN ### DOWN SHUTDOWN % ### %

SELECT RESET STROKES INT 1/2

Ref. Symbol Description

Press to reset intensifier one (1) stroke count RESET STROKES Press to reset intensifier two (2) stroke count

Press UP and DOWN arrows to increment or decrement OVERSTROKE SETPOINT or SHUT OVERSTROKE SHUTDOWN. DOW SHUTDOWN Because overstroke protection is related to N stroke speed under actual pressure setting, this % allows you to control sensitivity of the overstroke protection software for your particular operating pressure STROKES/MIN STROKES/MIN ... is actual stroke rate

01/2004 3 - 9

SECTION 3 OPERATION

STROKE INT 1 ####### COUNT INT 2 #######

SHUT STROKES/MIN ### DOWN SHUTDOWN % ### %

SELECT RESET STROKES INT 1/2

Ref. Symbol Description

The bar graph illustrates percent of capacity that the ACTUAL LOAD machine is presently running

... Set by using up/down keys. Set at 10% above running SHUTDOWN % SHUTDOWN % capacity to shutdown at operating conditions. Warning will be activated if less than 10 % below operating conditions

SELECT SET INTENSIFIER 1/2 button to “2” on dual intensifier units, and to “1” on single intensifier units. INTENSIFIER SELECT INT 1/2 Return Returns to Main Menu

01/2004 3 - 10

SECTION 3 OPERATION

SET-UP SCREEN

SET-UP

SCREEN

WATER IDLE RESET SHUTDOWN FUNCTION FUNCTION

TRANSDUCER PROPORTIONAL SELECT SELECT

There are two SET-UP SCREENS – If analog pressure control is not installed on the machine, a screen will appear that does not include the TRANSDUCER and PROPORTIONAL SELECT buttons. These buttons are used only if a pressure transducer and/or a proportional valve are installed on the machine Ref. Symbol Description Press on (I) to shut water off five (5) minutes after machine shuts down. Selecting this function will insure that the inlet cutting

WATER RESET WATER water is shut off following a shutdown fault. This can prevent water from leaking past a RESET damaged water seal following an overstroke FUNCTION shutdown caused by a seal failure.

Press on (I) to stop machine after 30 minutes of inactivity (machine not stroking). This

IDLE SHUTDOWN IDLE feature saves energy by automatically SHUTDOWN shutting down the intensifier if it is not being used FUNCTION

PROPORTIONAL ... select if proportional valve is installed SELECT PROPORTIONAL SELECT

TRANSDUCER ... select if pressure transducer is installed SELECT TRANSDUCER SELECT INDICATING PUMP Flashing bar indicates machine is on CONDITION

STOP BUTTON

01/2004 3 - 11

SECTION 3 OPERATION

MAINTENANCE SCREEN

MAINTENANCE SCREEN

LOGIC REV

PLC ######## ##

DISP 05141924 00

Start button will start unit in RECIRC mode Recirculation and will open dump valve.

Stop STOP button will stop unit.

Jog right will extend piston to the right giving Jog right full exposure to the right plunger once the unit is disassembled.

Jog left will extend piston to the left giving full Jog left exposure to the left plunger once the unit is disassembled.

CAUTION Unit must be completely assembled to use Jog functions.

01/2004 3 - 12

SECTION 3 OPERATION

ALARM SCREEN In ALARM condition, message/alarm will flash. Message will not be visible if alarm condition does not exist.

OVERSTROKE LEFT RIGHT T/W

Warning Warning Warning Pending Pending Pending OIL BOOSTER TEMP HIGH Temp High Press Low WATER PRESURE Inlet Low Outlet High

Ref. Symbol Description

OIL Indicates high oil temperature. High oil OIL Temperature temperature will shut the machine off 60 TEMP HIGH seconds after detection of this alarm condition

Low oil level will immediately shut the machine OIL Level off. This alarm will appear on the ALARM BANNER Alarm indicates low booster pump output BOOSTER pressure. Low booster pressure will shut down BOOSTER PRESS LOW the machine 40 seconds after alarm condition PRESSURE LOW is detected Alarm indicates high booster pump Booster Temp High temperature. The machine will shut down 30 Teperature seconds after this alarm condition is detected INLET LOW alarm indicates low booster outlet Booster Inlet Inlet Low water pressure. The machine will be shut off if Pressure the condition persists for 30 seconds OUTLET HIGH alarm indicates excessively HP Outlet high discharge water pressure. This alarm is Outlet High Pressure available only if a pressure transducer is installed on the machine Alarms indicate overstroke conditions. First a WARNING, then a PENDING SHUTDOWN alarm will occur. If condition persists the Overstroke OVERSTROKE machine will SHUTDOWN due to overstroke. This shutdown condition is indicated on the ALARM BANNER

01/2004 3 - 13

SECTION 3 OPERATION

NO PRESSURE CONTROL

THIS UNIT IS NOT EQUIPPED WITH PROPORTIONAL CONTROL

This screen will appear if the pressure control on main menu is selected and machine does not have PROPORTIONAL control.

The machine cannot be stopped from this screen.

01/2004 3 - 14

SECTION 3 OPERATION

LANGUAGE

LANGUAGE SCREEN

FRENCH GERMAN

SWEDISH ENGLISH

Scroll up and down for desired language and press ENTER to select FRENCH, GERMAN, ITALIAN, SWEDISH, or ENGLISH.

01/2004 3 - 15

SECTION 3 OPERATION

LEFT OVERSTROKE SHUTDOWN CHECK LEFT HP SEAL CHECK RIGHT DISCHARGE CHECK VALVE CHECK LEFT INLET CHECK VALVE

RESET

To reset the alarm does not mean that the alarm CAUTION condition has been cleared.

Recommended action must happen!

• When a shut-down condition occurs, an ALARM BANNER will appear hiding the current screen. The ALARM BANNER will display the type of shutdown and remedy to clear the alarm. • Pressing the reset button will clear the ALARM BANNER but does not clear the alarm. The banner will continue to appear until the alarm condition is cleared. • Shutdowns will appear on ALARM HISTORY SCREEN. • The ALARM BANNER shutdowns are: Banner Message Required Action Motor Overload check incoming voltage, check overload relay setting Motor Feedback Check motor starter relay Failure Oil Level Low Check the oil level on the reservoir, check for leaks Oil Temp High Check cooling water flow with a flow meter Low Booster Check the booster pressure adjustment and check Pressure booster condition Low Inlet Water Check water supply pressure at maximum flow rate Pressure Long Idle Time May be selected for energy saving Shutdown Overstroke Check plumbing for leaks, check HP orifice, check Shutdown for leaking HP check valves

01/2004 3 - 16

SECTION 3 OPERATION

Banner Message Required Action Booster Temp High Check incoming water temperature, check for long idle time Left Overstroke Check left high-pressure seal, check right discharge Shutdown check valve and check left inlet check valve Right Overstroke Check right high-pressure seal, check left discharge Shutdown check valve and check right inlet check valve T/W Overstroke Check plumbing for leaks, check for long idle time Shutdown

01/2004 3 - 17

SECTION 4 MAINTENANCE

Section 4 MAINTENANCE

4 Maintenance (4)

This section provides an overview of scheduled and preventive maintenance. In addition, maintenance of the five systems shown below is described in the respective sections. Refer to the following sections for detailed information on the operator console and systems maintenance: • Operator Console, Section 3 • Low Pressure Water, Section 6 • High Pressure Water, Section 7 • Electrical System, Section 8 • Hydraulic System, Section 9 • Recirculation System, Section 10

The following is an overview of the primary components and their location.

• Hydraulic Pump System – including electric motor, pump and hydraulic valve manifold block. The pump is a variable displacement, axial piston, pressure compensated type. • Oil Recirculation System – including a fixed displacement gear –gear pump, oil to water heat exchanger, hydraulic cartridge type oil filter, and related hydraulic hoses and fittings. The gear pump mounts to the back of the ·main hydraulic pump. This system is separate from the main hydraulic circuit and cleans and cools the hydraulic fluid whenever the main pump is running.. • Booster Pump System – includes a stainless steel positive displacement vane pump with pressure adjustment and high temperature switch, low pressure water filter, bypass relief valve, and associated water tubing and fittings. The booster pump is mounted to the back of the oil recirculation gear pump. • Intensifier System – includes one or two high-pressure (HP) attenuators, one or two hydraulic intensifier assemblies , a HP dump valve and associated HP piping and fittings.

01/2004 4 - 1

SECTION 4 MAINTENANCE

Item Description (1) Hydraulic Pump (2) Recirculation Pump (3) Booster Pump (4) Intensifier Assembly (5) Control Panel

01/2004 4 - 2

SECTION 4 MAINTENANCE

4.1 Scheduled Maintenance

Check Item to be Major 1 Description Checked Component Other As Req’d Per Shift Weekly Monthly 3-Month 6-Month Yearly Hydraulic Oil Oil Level X R Tank Fluid Level Oil Sample Hydraulic System F & Leak Hydraulic Hydraulic X X Checks Cartridge Seals Cylinder Plunger Seals HP Cylinder X X Sealing Head HP Cylinder X X Water Supply Low Pressure X X Pressure Filter Assembly Intensifier Pressure & Discharge HP Piping X Flow Checks Pressure Hydraulic Pump Hydraulic Pump X Pressure Plunger Seal HP Cylinder X X Tempera- HP Check Valve Port Sealing Head X X ture Checks Cooling Water Oil/Water Heat X F Inlet/Outlet Exchanger Motor Bearings Hydraulic Power Lubrication X R2 Lube Unit & Filter Hydraulic Oil Checks Hydraulic Filter X X R Tank Vibrations- Electric Motor F Rotating Hydraulic Pump F Equip. Motor-Female Splined Motor/Pump Spline Shaft Connection Piston Pump-Male L2 Service Spline Hydraulic Pump F HP Tubing, Valves, & F Fittings System Hydraulic Hydraulic Cleaning & F Manifold Intensifier Inspections Electrical Control Panel F Enclosure Hydraulic Pump & Gage Calibration F HP Piping Control X Lights Hydraulic Seal & Wear Intensifier R3 Piston Rings Hydraulic Cylinder

01/2004 4 - 3

SECTION 4 MAINTENANCE

Key: F: Information X: To be observed R: To be replaced L: To be replaced

1 Yearly or 4,000 hours, whichever comes first. 2 Manufacturer recommends motor bearings to be lubed at 12,000-hour intervals. 3 Recommended Overhaul Interval: 10,000 hours.

4.2 General Maintenance Proper maintenance is important for reliable and consistent performance. Preventive maintenance reduces unscheduled downtime, and extends component life. High-pressure water will cut almost anything it CAUTION contacts. Any leaks must be repaired immediately to

prevent damage or serious personal injury.

Maintenance Guidelines • Regular inspection of equipment is recommended. • Keep equipment and surrounding areas clean. • Check pressures, temperatures, and look for leaks. • Make repairs immediately. • Keep a repair log of all maintenance performed.

Work Area • Maintain a clean work area for repair and maintenance of the waterjet pump. • Use a clean work bench in a dust and dirt free work area. • Use lint-free material for wipe cloths. • When blowing off parts with compressed air, use only clean, dry air. When flushing parts with a solvent, use only clean, filtered fluid. • Always use original KMT Waterjet replacement parts, for consistent performance, reliability, safety, and to protect equipment warranty.

Safety Recommendations • Carefully read the Safety Guidelines in Section 1, of this manual. • Perform all lockout and tagout procedures prior to working on the intensifier. • Close all incoming supply valves and open all drain valves. • Close the nozzle valves and manifold valves. When the power is shut off, the safety dump valve will open and bleed off high pressure water stored in the discharge piping. 01/2004 4 - 4

SECTION 4 MAINTENANCE

• Provide suitable receptacles, pans, trays, etc. to catch and retain fluids to avoid a hazardous work area. • DOUBLE CHECK to insure that all pressure is relieved from the system before proceeding. Binding and Interference When assembling close tolerance machine parts, use extreme care in aligning them for assembly. Do not force the parts together. If parts bind during assembly, separate them and try again until they are successfully mated. NOTE It should never be necessary to force an assembly together. Plunger material is strong, but brittle. Avoid dropping, sharp blows, or heavy bending loads when working with these expensive parts. Make sure all parts are clean, free of burrs, metal particles, dirt, dust, etc. Use High Purity Goop (KMT Part 49864887), when assembling any high pressure fitting. After servicing any high-pressure components, flush the high pressure water system by operating the waterjet pump for a short period with the nozzle valve open and no orifice in place. Next, shut down the waterjet pump, install an orifice, and slowly increase the discharge water pressure in stages. Check all high pressure connections for leaks. Unusual requirements should be referred to the Technical Services group at KMT Waterjet. To contact the KMT Waterjet Spare Parts Department:

USA: Parts Department Europe: Spare Parts Manager KMT Waterjet Systems Waterjet Systems KMT Waterjet Systems 635 West 12th Street Auf der Laukert 11 Baxter Springs, KS 66713 D–61231 Bad Nauheim USA Germany Phone: (620) 856–2151 Phone: + 49–(0)6032–997–115 Fax: (620) 856–5050 Fax: +49–(0)6032–997–270 E-Mail: [email protected]

01/2004 4 - 5

SECTION 5 TROUBLE SHOOTING

Section 5 TROUBLESHOOTING

5 TROUBLESHOOTING (5)

5.1 TROUBLESHOOTING - Electrical

SL-IV Pump Will Not Start Condition & Possible Causes Corrective Action E-STOP Button Depressed Pull out E-STOP button. Check all remote E- STOP pushbuttons. Push CONTROL POWER ON button – white light on CONTROL POWER ON button should illuminate. Power Disconnected Check that main power is present. Check that main power disconnect is ON. Control Power Interrupted Check power supply circuit protection (tripped breaker). Check power supply (24vdc) input and output. Motor Overload Relay Find reason for overload. Reset overload relay. Tripped Protection Fault Activated Check LOW OIL LEVEL, HIGH OIL TEMPERATURE, OVERSTROKE CONDITION, or HIGH TEMPERATURE BOOSTER PUMP (bold letters indicate display messages) Inlet Water Valve Turned Reset water valve by pressing RESET on Run Off menu. Console Display and Lights Fail to Illuminate E-STOP Button Depressed Pull out E-STOP button. Check all remote E- STOP pushbuttons. Push CONTROL POWER ON button - white light on CONTROL POWER ON button should illuminate. Main Power Disconnected Check main power. Door Unlatched (locked Check that the door disconnect switch is properly out) engaged. Control Power Not Check power supply circuit protection (tripped Available breaker). Check power supply (24vdc) input and output. Pump Quit Running Unsafe Operation Detected Check fault indication on operator’s console and correct: LOW OIL LEVEL, HIGH OIL TEMPERATURE, OVERSTROKE CONDITION, or HIGH TEMPERATURE BOOSTER PUMP. Electrical Power Check power supply circuit protection (tripped Interruption breaker). Check power supply (24vdc) input and output. Check that main power is available. Motor Overload Relay Find reason for overload. Reset overload relay. Tripped

01/2004 5 - 1

SECTION 5 TROUBLE SHOOTING

No Control Power (24vdc) Circuit Breaker Tripped Check input circuit breaker of power supply. Check output circuit breaker (24vdc) of power supply. Power Supply Fault Check power supply input and output voltages. No Control Power (24vdc) E-stop Button Depressed Pull out E-stop button. Check all remote E-stop pushbuttons Control Power On Button Check for voltage through switch when button is pushed. MCR Relay Not Energized Check to see if coil is pulling in on the master control relay (MCR) MCR Contact Set Failure Check to see if contact sets on MCR are changing state when MCR is energized. Flashing Light, Message On Operator’s Console Condition and Possible Causes Corrective Action Overstroke Check for HP piping leaks. Check for HP seal leak.Check air pressure. Check booster pump pressure. Check for HP check valve leaks. Check for HP valve leaks. Check for sufficient water supply Check for dump valve closure or seal leakage. Check orifice condition, and proper diameter. OIL TEMP Verify hydraulic oil tank temperature is above 620C (1440F). Check output pressure of oil recirculation pump. Check cooling water flow to heat exchanger. Adjust water modulating valve. OIL LEVEL Check hydraulic oil level on the reservoir sight . Check for and correct hydraulic oil leak, add oil to tank. If reservoir is full, check oil level switch. Booster Pump Hot Check if booster pump temperature is above 530C (1280F).Check cutting water flow to/from booster pump.Check water bypass orifice. Check excessive time in deadheaded condition. Check booster pump temperature switch.

01/2004 5 - 2

SECTION 5 TROUBLE SHOOTING

5.2 TROUBLESHOOTING – HP WATER

HP Water Signal Abnormal Fluctuation Orifice Large/ Worn/ Check that orifices in use do not exceed capacity Damaged of pump. Check that orifices are in good working order. rify that a jewel is not missing from the orifice mount. Check Piping Leaks Check system components for leaks including dump valve condition. Check Valve Leakage Inspect pump discharge HP check valves. Inspect pump inlet low pressure (LP) check valves. Check Seal Leakage Inspect plunger and sealing head seals. Hydraulic Control Check hydraulic valve operation. Malfunction Verify proper shifting of 4-way directional control valve. Verify proper proximity switch operation. Check Cutting Water Pressure of cutting water supply to intensifier Supply should be at least 2 bar (30 psi). Hot Surfaces On HP Cylinder Components HP Discharge Check Inspect check valve seat, poppet, spring, and Leaking spring guide condition and sealing head. LP Inlet Check Valve Inspect check valve poppet, spring, o-ring, poppet Leaking retaining , and sealing head. Sealing Head or Plunger Check plunger and sealing head for erosion scratches or mechanical damage and replace if necessary. Damaged HP Cylinder Check cylinder bore for damage. Polish if required. Oil or Water Leaks from HP Cylinder Weep Holes Condition and Possible Causes Corrective Action Oil Leak HP Intensifier Check hydraulic cylinder O-ring and back-up ring for leakage. Check proximity switch and spacer O-ring area for oil leakage. Replace hydraulic seal (cartridge) and clean holes in hydraulic seal retaining flange.

01/2004 5 - 3

SECTION 5 TROUBLE SHOOTING

Oil or Water Leaks from HP Cylinder Weep Holes Water Leak at HP Plunger Replace seal assembly if leak exceeds one drop in Seal 10 strokes. Check plunger surface and cylinder bore for build-up of seal material and polish off with 600 , polishing the cylinder circumferential and plunger any direction Check Plunger surface and cylinder bore for scratches circumferential and longitudinal, if any are found, contact IR for possible rework and polishing. Check plunger for dull finish, contact IR for polishing. Water Leak at Sealing Check seal assembly. Head Seal Check for scratches on inside diameter of HP cylinder. Polish if required. Check for scratches in area of sealing head seal. Polish if required. HP Check Valve Leak If there are no visible HP water leaks, but there are higher temperatures on HP cylinder or sealing head, this indicates a HP or LP check valve leak. Use corrective action listed in section “PROCEDURE – HP WATER CHECK VALVE TROUBLE SHOOTING” for both discharge and inlet checks: Normal Temperature, but Check Valve Problem Low Hydraulic Pressure Follow the instructions for HP check valve leak Setting described in section “PROCEDURE – HP WATER CHECK VALVE TROUBLE SHOOTING” HP Cutting Water Too Low Low Hydraulic Pressure If in LO, turn pressure switch to HI. Check Setting hydraulic pump pressure setting. Restricted or No Cutting Check cutting water supply flow and pressure Water Supply Water Filter Clogged Check pressure differential at filter gages, and replace elements if exceeds 1 bar (15 psi) while the pump is operating. Check HP line filter for collapsed element. Air Trapped Bleed air from cutting water plumbing.

01/2004 5 - 4

SECTION 5 TROUBLE SHOOTING

5.3 TROUBLESHOOTING – LP WATER

Low Booster Pump Pressure Booster pump pressure If at anytime the pump is running and the below 5 bar (70 psi) booster pump pressure falls below 5 bar (70 psi), adjust the relief valve clockwise to increase the pressure above 5 bar (70 psi). If the booster pump pressure cannot be adjusted above 5 bar (70 psi), replace the booster pump. Booster pump pressure If at anytime the pump is running and the above 8,5 bar (125 psi) booster pump pressure is above 8,5 bar (125 psi), the relief valve is opening up and sending water to the drain. Hot Hydraulic Oil Restricted or No Cooling Check cooling water flow to and from heat Flow exchanger. The water pressure differential across the heat exchanger, 2.75 bar (40 psi) minimum required for flow through the exchanger. Check operation and setting of water modulating valve. Water Modulating Valve Check and adjust setting of water modulating Setting valve. Compressing spring (clockwise) slows water flow and increases temp; reducing spring tension (counterclockwise) increases water flow and lowers oil temp. Heat Exchanger Clogged Flush heat exchanger, improve flow of cooling water or replace heat exchanger. Recirculation Pump Replace hydraulic oil filter.If filter is new, replace Hydraulic Pressure below recirculation pump. 1,5 bar (20psi) Hydraulic Pressure but no High Pressure Water Pressure Proximity switch failure Verify left hand and right hand LED lights on DC alternately illuminate ON/OFF. If so, both proximity switches are properly functioning. If both the green and red LED lights are on at the same time on one proximity switch, replace the proximity switch. Flag the proximity switches one at a time, checking to see if it is sending a signal to the PLC. Hydraulic Pressure but no High Pressure Water Pressure I/O relay failure Check if PLC output is shifting the I/O output relays and allowing power to go to the coils on the directional valve. Directional valve coil Check coils on the directional valve with a volt failure meter to verify good or bad

01/2004 5 - 5

SECTION 5 TROUBLE SHOOTING

Hydraulic Pressure but no High Pressure Water Pressure PLC failure If there are inputs from the proximity switches but no outputs, contact IR service for a logic review and verification of PLC failure.

5.4 SPECIAL PROCEDURE—HP WATER CHECK VALVE TROUBLESHOOTING

5.4.1 HP Check Valve Troubleshooting A leaking HP check valve is suspected if either HP cylinder or sealing head is unusually hot. Compare temperatures of opposing sealing heads or HP cylinders to decide location of hot spot. Note any heat in LP water ring or hose fitting attached to LP water ring.

5.4.2 OUTLET HP Check Valve – Troubleshooting

NOTE An alternative approach is to switch the HI/LO hydraulic pressure control switch to LO pressure, which should slow the stroke rate enough to hear a difference in plunger motion between HP cylinders. Study the LED’s on the HP cylinders to decide in which direction the hydraulic piston is moving rapidly, then decide which pair of INLET and OUTLET check valves are suspect.

1. Start IRWJ pump. Set HP water to above 45,000 psi. 2. Close HP water nozzle valve (deadhead IRWJ pump) 3. Note pressure indication on HP water pressure gage. 4. Turn IRWJ pump OFF, allowing HP water to remain trapped in HP piping and HP attenuator. 5. Wait approximately 60 seconds to see if HP water pressure “bleeds” down 6. If gage pressure “bleeds” downward, then one of the HP OUTLET check valves is the likely leak path.

NOTE If the HP water nozzle valve is leaking, or if HP leaks exist elsewhere in the HP water manifold, then the above test is less valid.

If the “bleed-down” test shows a leaking OUTLET HP water check valve, and if one HP cylinder or sealing head is noticeably warmer than the other, then the OUTLET check valve in that hot sealing head is probably leaking. If this OUTLET HP check valve is not the problem, then continue to troubleshoot the INLET cutting water check valves.

Note that cutting water entering the sealing head through the LP water ring is normally cool. Any heat in the LP water near a sealing head is an indication of HP water escaping from the HP cylinder back through the INLET cutting water check valve.

01/2004 5 - 6

SECTION 5 TROUBLE SHOOTING

5.4.3 INLET Cutting Water Check Valve – Troubleshooting NOTE An alternative approach is to switch the HI/LO hydraulic pressure control switch to LO pressure, which should slow the stroke rate enough to hear a difference in plunger motion between HP cylinders. Study the LED’s on the HP cylinders to decide in which direction the hydraulic piston is moving rapidly, then decide which pair of INLET and OUTLET check valves are suspect.

1. With IRWJ intensifer pump turned OFF, close a HP hand valve located in the HP piping manifold between the IRWJ pump and the cutting station. 2. Open this HP hand valve approximately one turn. 3. Start IRWJ intensifier pump, switch or adjust pressure to high pressure (greater than 45,000 psi), then open HP nozzle valve. 4. Without closing the HP hand valve, slowly turn hand valve handle in the CLOSE direction, until a difference in stroke rate, i.e., a short stroke in one direction, alternating with a long stroke in the opposite direction is noticeable.

NOTE Do not close the HP hand valve, but rather leave it at the metered position giving the SHORT / LONG / SHORT / LONG stroking sequence.

5. Observe LED lights on the hydraulic directional control valve (located above the main hydraulic pump). Identify whether the left hand (LH) or right hand (RH) LED light corresponds with the short stroke established in Step 4 above. 6. If, e.g., the LH LED indicates short stroking in that direction, then either the leak is in the RH INLET cutting water check valve or the LH OUTLET HP water check valve. 7. Conversely, if the RH LED indicates short stroking in the Right Hand HP cylinder, either the LH INLET cutting water check valve or the RH OUTLET HP water check valve is at fault. 8. Combining the results of the dead head/ bleed down test described in paragraph 5.5.2 above with the short stroke test described in steps 4 and 5 above, determine which HP cylinder (LH or RH) HP OUTLET check valve is at fault. NOTE The bolted flange / metal-to-metal seal arrangement of the SL-IV / SL-IV sealing head make the INLET check valves much more difficult to access for maintenance than the HP OUTLET check valves. Therefore one should generally rule out problems with the OUTLET HP check valves prior to disassembling the INLET check valves.

01/2004 5 - 7

SECTION 6 LOW PRESSURE WATER SYSTEM

Section 6 LOW PRESSURE WATER SYSTEM

6 LOW PRESSURE WATER SYSTEM - Features (6)

The SL-IV Waterjet Pump is equipped with two low pressure circuits: • Cutting water supply for HP intensifier assembly. • Cooling water supply for the oil-to-water heat exchanger. The low pressure water system supplies the pump with the following: • Water of sufficient cleanliness and pressure to the inlets of the two (2) HP cylinders. • Cooling water of sufficient flow rate and low temperature to the oil-to-water heat exchanger.

6.1 Oil Cooling Water Supply

The oil cooling water supply circuit includes the water modulating valve. Refer to Figure 6.1 for a schematic diagram of the oil cooling water circuit. See “Recirculation System” Section 10.2 for details on adjustment of water modulating valve (2). The maximum flow rate of the cooling water is specified in Section 11 “Specifications” under “Hydraulic Oil Cooling.” A minimum inlet pressure of 2.8 bar (40 psig) and 21 deg C (700 Fahrenheit) maximum inlet temperature is required to maintain oil temperature under extreme operating conditions.

6.2 Cutting Water Supply

Refer to Figure 6.2 for a schematic diagram of the LP cutting The cutting water supply circuit. Refer to the Parts Lists (Section 12) for detailed component information on the LP cutting water circuit. The LP water supply includes the following: • Low pressure water filter • Inlet water shutoff valve (solenoid operated) • Booster pump driven by main motor Several pressure gages and switches, and a temperature switch. Most components in the LP cutting water supply circuit are stainless steel or neoprene or other plastic. A stainless steel inlet solenoid shutoff valve (11) is available on request. Pressure and temperature switches are connected to a PLC located in the electrical enclosure. The PLC which monitors out-of-tolerance conditions, including the following: • Low water pressure at the booster pump inlet [switch (17)]. • Low water pressure at the intensifier inlet [switch (16)]. • High temperature at the booster pump outlet [switch (2)]. • If the motor does not run for 2 minutes, the solenoid valve (11) will shut off. To re-open the valve, select RUN SCREEN.

01/2004 6 - 1

SECTION 6 LOW PRESSURE WATER SYSTEM

Note that pressure gages are installed in a frame leg for easy access. Pressure gages provide a qualitative measure of LP water system performance, while pressure switches provide automatic shutdown protection against out of tolerance conditions.

6.2.1 Normal Operating Condition During normal operation, the low pressure water system maintains the following conditions: • Filter pressure drop (gage reading 4 minus 6) not more than 1 bar (15 psi) • Booster pump inlet pressure: min 2,5 bar /35 psi; max 5 bar / 73 psi. Important: inlet pressure must be constant. • Booster pump discharge pressure gage reading 8.0-8.3 bar (115-120 psi) • Intensifier LP cutting water supply pressure greater than 4 bar (60 psi). • Water at booster pump outlet maintained at less than 53,3 °C / 128 deg-F. NOTE While the intensifier assembly reverses direction, the booster pressure will fluctuate slightly above and below the normal setting. Pressure fluctuation greater than 2 bar (30 psi) may indicate inadequate water supply to unit, or poor booster pump performance.

6.2.2 Operation The cutting water enters the pump through port “B”. When the CONTROL POWER ON button on the operator control panel is activated, solenoid valve (11) opens allowing water to flow through filter assembly (5), then to the inlet of the booster pump (1). The booster pump increases cutting water supply pressure to 8 bar (120 psi) to assure proper supply to both intensifier inlet check valves (13). Pressurized water from the booster pump is supplied to manifold (18). From this manifold, cutting water is routed to the inlet check valves (13) of the intensifier. Note that if NOTE a redundant intensifier is installed, the inlet cutting water must be manually disconnected from the inactive intensifier, then connected to the inlet check valves of the inactive intensifier. NOTE The booster pump (1) is factory set to deliver 8 bar (120 psi) with an inlet pressure at port “B” of 4 bar (58 psi). The pump may require adjustment if local inlet pressure is different, because discharge pressure depends on inlet pressure. Inlet pressure is affected by filter condition, as well as local water supply conditions. The LP water filter (5) is located ahead of the booster pump to protect the pump as well as the intensifier and other HP components. The filter gages (4 and 6) indicate the condition of the filter. A difference of 1 bar (15 psi) indicates a dirty filter element that should be replaced.

01/2004 6 - 2

SECTION 6 LOW PRESSURE WATER SYSTEM

Item Description 1 Booster Pump 13 Intens. Inlet check Valve (2 ea) 2 Temperature Sensor 14 Pressure Gage 3 Pressure Control Valve 15 Intensifier 4 Pressure Gage 16 Pressure Switch (60 psi) 5 Filter Head 17 Pressure Switch (30 psi) 6 Pressure Gage 18 Manifold, LP Water 7 Orifice 19 Relief Valve 8 Filter Element 20 Air Bleed Valve 9 Check Valve 21 Electric Motor 10 Relief Valve 11 Inlet Solenoid Valve 12 Filter Housing

01/2004 6 - 3

SECTION 6 LOW PRESSURE WATER SYSTEM

Figure 6.2 LP Cutting Water Supply Circuit

Figure 6.3 LP Water Cooling Circuit Item Description 1 Water/Oil Heat Exchanger 5 Recirculating Hydraulic Pump 2 Water Modulating Valve 6 Water Booster Pump 3 Hydraulic Filter 7 Main Hydraulic Pump 4 Hydraulic Reservoir 8 Electric Motor

01/2004 6 - 4

SECTION 6 LOW PRESSURE WATER SYSTEM

6.2.3 Booster Pump The LP cutting water circuit (refer to Figure 6.2) incorporates several features relating to the booster pump: a. Booster pump overpressure protection—relief valve (3) is built into the booster pump body and is intended to prevent excessive pump outlet pressure. This relief valve typically operates when the intensifier is dead- headed. b. If either check valve (13) leaks, the circuit and booster pump could be subjected to HP water from the intensifier. Inline relief valve (10)—provides circuit and booster pump protection in the event of a leaking check valve (13) at the intensifier. c. High cutting water supply pressure could result if circulation were blocked as with dead headed HP water flow. Orifice (7) and check valve (9) allow a minimal amount of LP water to circulate through the filter back to the pump inlet, thereby reducing the likelihood of overheating the cutting water. d. If temperature of cutting water at the booster pump outlet is too high, then temperature switch (2) activates an automatic shutdown circuit in the PLC that stops the main electric motor (pumps stop rotating). Note that temperature switch (2) is located on manifold (18) e. If water pressure to the booster pump inlet is too low, then the pump might be starved, resulting in pump damage. Pressure switch (17) activates an automatic shutdown circuit in the PLC when pressure drops below the switch setting. Logic in the PLC ignores momentary low pressure signals that might result in erroneous shutdown commands. Typical conditions likely to cause low booster pump inlet pressure are clogged LP filter or problems with the customer-supplied cutting water pressure.

6.2.4 Low Pressure System Protection The booster pump pressure relief valve (3) is adjusted by turning with a flat blade . Turn clockwise to increase pressure or counterclockwise to decrease pressure. Some booster pumps have an exposed adjustment screw, while on others the adjustment screw is accessed by removing screw is accessed by removing an acorn nut. System pressurization over 8.6 bar (125 psi) is prevented by the relief valve (10). Pump overheating due to lack of water, or long deadheaded conditions, is prevented by the temperature switch (2) on the booster pump (1), which turns the pump off. To reduce booster pump overheating while deadheaded, water is recirculated through orifice (7) and backflow check valve (8) to the booster pump inlet.

Pressure Settings Pressure Adjustment Control # bar (psi) Increase Decrease Maximum Minimum Booster Counter- 3 Clockwise 8.3 (120) 8.0 (115) Pressure clockwise Booster 10 Fixed Fixed 9.0 (130) 8.6 (125) Relief

The cutting water supply circuit is automatically shut off after the motor has been off for 2 minutes. To reset the water supply valve, select RUN SCREEN.

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SECTION 6 LOW PRESSURE WATER SYSTEM

Automatic shutoff of the cutting water supply prevents unnecessary water spillage in the event of an external leak that triggers an automatic shutdown on an unattended IRWJ pump.

6.3 Maintenance Overview In order to maintain necessary fluid pressure for the pump and to keep the water clean for proper operation it is necessary to replace on the water filter and/or adjust the booster pump. The guidelines for servicing these parts are described below.

6.3.1 Water Filter Service Replace filter elements when there is a 1 bar (15 psi) pressure differential between gages (4) and (6):

Components: Bleed Valve Element Head Housing Recommended Tools: Supplied filter thread/unthread tool (to turn housing) Container (to capture some water spill) Rags Parts: Elements for water: 10 micron (quantity 2) Polymer mixture: 40 micron (quantity 2)

Water Filter Element Replacement Procedure 1. Turn off cutting water supply 2. Press bleed valve to relieve trapped pressure 3. Unscrew housing from head. Remove element. 4. Install new elements in housing. Screw housing into head. 5. Open cutting water supply. 6. Press bleed valve to remove trapped air. 7. Start waterjet pump. Verify satisfactory pressure readings.

6.3.2 Booster Pump If booster pressure, as read on the booster pump discharge pressure gage (14) is less than 8.0-8.3 bar (115-120 psi), the booster pump needs to be adjusted.

Components: (1) Booster pump (3) Pressure control knob Recommended Tools: Flat screwdriver (To turn pressure control knob) Container (To capture some water spill) Rags

Parts: None required

Booster Pump Adjustment Procedure 01/2004 6 - 6

SECTION 6 LOW PRESSURE WATER SYSTEM

1. Turn on cutting water supply 2. Start waterjet pump and observe booster discharge pressure 3. Stop waterjet pump and press E-Stop button. 4. Remove acorn nut from the side of the booster pump and turn screw clockwise to increase pressure or counter-clockwise to decrease pressure. 5. Replace acorn nut, restart waterjet pump and observe booster discharge pressure. 6. Repeat steps 4 and 5 if necessary.

01/2004 6 - 7

SECTION 7 HIGH PRESSURE WATER SYSTEM

Section 7 HIGH PRESSURE WATER

7 High-Pressure (HP) Water (7) The high pressure (HP) water system takes the relatively low pressure water inlet to up to maximum pressure in excess of 3,400 bar (50,000 psi) supplying orifice diameters appropriate to the waterjet pump’s operating power (See Specifications, Section 11).

7.1 Components The HP water components include the hydraulic intensifier, HP attenuator(s), HP dump valve, HP pressure indicator (optional), and HP piping. Maintenance on the intensifier is discussed in detail in this section. In addition to HP components and assemblies, the hydraulic cylinder features of the intensifier are discussed in this section.

Item Description (1) Bulkhead Fittings (2) Inlet Check Valve (3) Discharge Check Valve (4) HP Cylinder (5) Sealing Head (6) Sealing Head Nut (7) HP Attenuator (8) Hydraulic Cylinder (9) Hydraulic Piston (10) HP Dump Valve

7.2 Intensifier Disassembly and Reassembly

Detailed instructions are provided on disassembly and reassembly of the hydraulic intensifier, including HP seal maintenance. A discussion of detailed inspection and repair for individual HP components and subassemblies is also provided. The HP attenuator is discussed but no disassembly procedures are

01/2004 7 - 1

SECTION 7 HIGH PRESSURE WATER SYSTEM

included. Note that HP attenuators are not considered to be serviceable by the customer.

Item Description (1) HP Cylinder (2) Plunger (3) Sealing Head (4) Hydraulic Cylinder Head (5) HP Seal (6) Ring (7) Ring Flange (8) Hydr Seal Cartridge (9) Retaining Flange (10) Stud (11) Cylinder Liner (12) O-ring (13) End Flange (14) Retainer Ring (15) Hydraulic Cylinder (16) Back-up Ring (17) O-ring (18) Cap Screw (19) Proximity Switch (20) Cap Screw (21) Piston Assembly (22) Hex Nut

Standard HP gland nut hex sizes for HP piping is as follows: • 3/8” HP fittings: 13/16” (open end) wrench. • 9/16” HP fittings: 30mm (1-3/13”) wrench. • Tie bolts nuts: 1-7/16” socket (7/8” and 1-1/8” plunger models)

01/2004 7 - 2

SECTION 7 HIGH PRESSURE WATER SYSTEM

7.2.1 HP & LP Water Piping

Disconnect from/Reconnect to Waterjet Pump

WARNING Before performing maintenance on the waterjet pump observe electrical LOCK OUT/TAG OUT procedures.

1. Loosen and remove HP Piping attached to the discharge HP check valve. Move tubing to clear work area. 2. For servicing the discharge HP check valve on the intensifier assembly, refer to section 7.3.1.”Discharge HP Check Valve”. Note that the sealing head can be removed with the discharge HP check valve attached. 3. Disconnect LP water at end flange. Note that to service the sealing head, including the inlet HP check valve, the tie bolts must be loosened allowing removal of the end flange. 4. With the HP piping and the LP cutting water plumbing disconnected, the following operations can be performed: • HP cylinder can be removed from hydraulic cylinder head • HP plunger seal can be serviced • After the pump has been reassembled, then the HP water piping and LP water disconnect are reinstalled as follows: 5. Slide inlet water collar over sealing head until it rests against the head nut. Connect LP inlet water quick disconnect to collar. 6. Install the HP water piping to the intensifier. Check HP fittings for proper collar position (1 to 1-1/2 threads exposed) and for adequate thread lubricant (High Purity Goop). Turn on cutting water supply and check for low-pressure leaks.

Check that all proximity switches are properly installed and secured prior to starting the motor. Failure to CAUTION tighten proximity switch hold down (2 each per

proximity switch) will result in hydraulic oil spraying in general directions.

7. Start the waterjet pump. Operate at low pressure (without a cutting orifice) to flush the HP passages, then operate at high pressure with orifice installed to check for leaks.

01/2004 7 - 3

SECTION 7 HIGH PRESSURE WATER SYSTEM

7.2.2 HP Cylinder “Jug” (HP Cyl., Sealing Head, Flanges, & Studs)— Disassembly / Re-assembly

NOTE IRWJ recommends removing the HP cylinder/ sealing head/ flanges AS AN ASSEMBLY for servicing the plunger HP seals, plunger, hydraulic seals, etc. IRWJ DOES NOT recommend loosening stud nuts except to service the sealing head inlet HP check valve, cone seat, etc. Refer to Table 7.1 for recommended disassembly / re-assembly practices. Due to the weight (approx. 70 lbs) of the HP cylinder jug, adequate support should be provided to prevent damage to the plunger or seals during disassembly/ re-assembly. See below listed overview for suggested special tools to support the HP cylinder jug for this procedure.

Item Description (1) Vee Block Cradle 05149877 (2) Plunger Removal Tool 05004924 (3) Seal Removal Tool 10148674 (4) 3/8” Plug 10079523 (5) 3/8” Gland 10078129 (6) Cylinder Wrench 05066139 (7) Tool-Stand Seal Removal 05149802

HP Cylinder Jug Removal 1. Prior to removing electrical power from the IRWJ pump, extend plunger on end to be serviced. Remove connector from proximity switch on end of hydraulic cylinder closest to HP cylinder jug to be removed. Start IRWJ pump in LOW pressure mode, allow approximately 20 seconds for appropriate startup and cycling of intensifier to extend and stop toward the disconnected proximity switch. Shut off IRWJ pump, shut off LP water supply, observe LOCK-OUT/ TAG-OUT safety rules.

01/2004 7 - 4

SECTION 7 HIGH PRESSURE WATER SYSTEM

Before performing maintenance on the waterjet pump CAUTION observe electrical LOCK OUT/TAG OUT procedures.

2. Disconnect HP and LP piping / hoses per paragraph 7.2.1 above. 3. With support cradle tool located under HP cylinder jug, unthread and remove jug from plunger and hydraulic cylinder head. NOTE several methods for rotating the HP cylinder jug are available. The cylinder wrench is available, or the jug can be rotated by hand with the help of the studs and stud nuts. A slight lift force applied to the HP gland nut of the outlet HP check valve can help ease the effort of rotating the HP cylinder jug.

HP Cylinder Jug Re-Installation 1. Verify that HP cylinder threads are adequately lubed with High Purity Goop and that the threads have been sanded/ dressed if galling was encountered during HP cylinder jug removal. 2. Verify that the HP plunger seals, packing follower, and plastic cylinder liner tube are correctly installed. Align HP cylinder jug with plunger using cradle tool to support weight and provide approximate alignment. Carefully push/ lift jug into place until threads are ready to engage. 3. While lifting upward on the outlet HP check valve gland nut, push upward on a stud nut, rotating the jug CW, while pushing inboard and upward until thread engagement is accomplished. Continue to thread HP cylinder into hydraulic cylinder head until hand tight. 4. Re-connect HP and LP piping / hoses per paragraph 7.2.1 above.

Check that all proximity switches are properly installed and secured prior to starting the motor. Failure to CAUTION tighten proximity switch hold down screws (2 each per

proximity switch) will result in hydraulic oil spraying in general directions. 5. Restart IRWJ pump, first operating in LOW pressure mode to flush out air in HP components and also to check for obvious leaks. Switch to HIGH pressure after 5-10 minutes of LOW pressure operation, watching for obvious leaks. Be ready to shut off the pump if leaks appear. Remedy leaks then repeat start procedure, moving from LOW pressure to HIGH pressure soon after intensifier starts pumping water (no further need to flush air from lines).

7.2.3 Stud Nuts and End Flange, Sealing Head—Disassembly / Re-assembly NOTE IRWJ recommends removing the HP cylinder/ sealing head/ flanges AS AN ASSEMBLY for servicing the plunger HP seals, plunger, hydraulic seals, etc. IRWJ DOES NOT recommend loosening stud nuts except to service the sealing head inlet HP check valve, cone seat, etc. Refer to Table 7.1 for recommended disassembly / re-assembly practices.

01/2004 7 - 5

SECTION 7 HIGH PRESSURE WATER SYSTEM

End Flange and Sealing Head Removal 1. Prior to removing electrical power from the IRWJ pump, extend plunger at intensifier end to be serviced. Remove connector from proximity switch on end of hydraulic cylinder closest to HP cylinder jug to be removed. Start IRWJ pump in LOW pressure mode, allow approximately 20 seconds for appropriate startup and cycling of intensifier to extend and stop toward the disconnected proximity switch. Shut off IRWJ pump, shut off LP water supply, observe LOCK-OUT/ TAG-OUT safety rules.

CAUTION Before performing maintenance on the waterjet pump observe electrical LOCK OUT/TAG OUT procedures.

2. Disconnect HP and LP piping / hoses per paragraph 7.2.1 above. 3. Loosen stud nuts, then remove nuts. 4. Remove end flange. Note that sealing head may be removed with end flange. 5. Remove sealing head. Note that a white plastic ring used to position the sealing head relative to the HP cylinder bore may not have been removed with the sealing head. This ring should be removed prior to re-installing a sealing head to avoid pushing the ring further into the HP cylinder bore. Note that a fully- assembled spare sealing head greatly reduces pump downtime. Re-Assemble Sealing Head and End Flange to HP Cylinder 1. Verify that sealing head cone surface is smooth. Perform any necessary maintenance on inlet check valve. (Refer to paragraph 7.3.2) Verify that a white plastic alignment ring is installed on the ‘nose’ of the sealing head. Verify O-rings (2 ea) properly installed in ID grooves of end flange. Check HP cylinder bore to verify presence of plastic tubular cylinder liner and to verify that no white plastic alignment ring remains in end of HP cylinder bore. Feel sealing edge of HP cylinder bore to verify that no unusual blemishes are present that might hinder proper cone ring seal. 2. Install sealing head into end flange. Install sealing head and end flange over stud bolts and into cylinder bore. Note that end flange should be oriented with the LP water fitting oriented near the 9 o’clock or 3 o’clock positions for ease of making the LP water connection. 3. Thread nuts onto studs to hand-tightness. Verify end flange and ring flange are parallel to within 0.070-inch. 4. Tighten stud nuts (using a ) in a crossing pattern in several stages to reach maximum torque. See Table 7.1 for suggested nut tightening sequence. Verify flange parallelism at completion of tightening sequence. 5. Re-connect HP and LP piping / hoses per paragraph 7.2.1 above. Verify that proximity switches (2 ea) are properly CAUTION installed Failure to tighten proximity switch hold down screws will result in hydraulic oil spraying in general directions. 6. Restart IRWJ pump, first operating in LOW pressure mode to flush out air in HP components and also to check for obvious leaks. Switch to HIGH pressure after 5-10 minutes of LOW pressure operation, watching for 01/2004 7 - 6

SECTION 7 HIGH PRESSURE WATER SYSTEM

obvious leaks. Be ready to shut off the pump if leaks appear. Remedy leaks then repeat start procedure, moving from LOW pressure to HIGH pressure soon after intensifier starts pumping water (no further need to flush air from lines).

7.2.4 HP Plunger Seal Service-- Disassembly / Re-assembly 1. Remove HP and LP piping/ hose, then remove HP cylinder jug following procedure 7.2.2, above. 2. Thread HP plug and gland fitting (items C1 & C2, Special Tools, Table 7.3) into HP check valve gland nut. Hand tight is sufficient. 3. Stand HP cylinder jug upright with stud nuts resting on platform of blocks or stand tool item (B), Table 7.3.

HP cylinder jug is heavy and if it is stood on top pan of DANGER IRWJ pump, will present a falling object hazard. Take

care to properly support jug so that it will not fall. 4. Fill HP cylinder bore with water, then fit a used plunger or seal removal tool (item (E), Table 7.3) into packing follower. Note that wrapping a shop rag around the plunger at the packing follower avoids splash-back. Use a dead blow to strike the button end of the plunger as though attempting to drive the plunger into the HP cylinder. This technique should ‘hydraulic’ the HP seal components upward onto the plunger/ tool shaft and out of the HP cylinder.

5. Slip plastic liner tube from bore of HP cylinder, inspect for possible heat or wear damage or for possible debris. Feel ID of HP cylinder for approximately 1-inch into bore. Sand any obvious ridges or grooves with 600-grit wet/dry sandpaper. Note that grooves or ridges are typically caused by seal debris buildup rather than by marks in ID wall of HP cylinder.

6. Inspect plunger surface for flaws. Rotate plunger 360- degrees by hand while viewing light reflection on plunger surface to note any dullness, streaks, pits or other defects. Run fingernail perpendicular to direction of suspected surface flaws to gage severity of defects. Depending on seal life achieved with removed HP plunger seal, make judgment regarding whether to replace plunger. Refer to Paragraph 7.2.6 for procedure regarding plunger removal/ installation.

7. Lightly coat seal components with FML grease prior to installing seal parts on plunger. Install new HP plunger seal assembly onto plunger, referring to appropriate diagram in Figure 7.___ for proper seal component orientation. Note that steel spring inside U-cup (if so equipped) can be easily distorted. Verify that U-cup spring, lips and cavity appear uniform prior to installation. NOTE Bronze packing follower intended to fit tightly on plunger. If follower is too tight to slip onto plunger, try heating follower in hot water. Then attempt to slip follower over plunger. 8. Slip plastic cylinder liner tube over plunger.

9. Install HP cylinder jug to hydraulic cylinder head per paragraph 7.2.2. 01/2004 7 - 7

SECTION 7 HIGH PRESSURE WATER SYSTEM

01/2004 7 - 8

SECTION 7 HIGH PRESSURE WATER SYSTEM

TABLE 7.1 FLANGE NUT TORQUE SPECIFICATIONS 7/8” Diameter Plunger 1-1/8” Diameter Plunger Plunger Diameter (SL-IV Plus) (SL-IV 100S) No. of Studs, Tightening 6 each (Fig A) 8 each (Fig B) Sequence Units N-m Ft-Lb. N-m Ft-Lb. 1st Stage Hand Tight Hand Tight Hand Tight Hand Tight 2nd Stage 135 100 135 100 3rd Stage 200 150 200 150 4th Stage 257-285 190-210 257-285 190-210 Max Out-of Parallel 1.8mm 0.070” 1.8mm 0.070” Size 1-7/16” 1-7/16” 6 BOLT CROSSING PATTERN: 8 BOLT CROSSING PATTERN

01/2004 7 - 9

SECTION 7 HIGH PRESSURE WATER SYSTEM

Table 7.2 HP INTENSIFIER SERVICE TEARDOWN SEQUENCE Disassemble/Re-assemble HP Cylinder Retainer Intensifier Related Stud Nuts Hydraulic LP Water Sealing Head, Flanges & Component Component HP Piping & End Cylinder Plumbing Flanges & Hydraulic Maintenance Assembly Flange Head Studs [1] Cartridge Ref Part No. -- 7.2.1 7.2.1 7.2.2 7.2.3 7.2.5 7.2.6 1 Outlet HP Check Sealing Head Yes No No No No No Valve 2 Inlet HP Check Sealing Head Yes Yes No Yes No No Valve 3 HP Plunger Seal HP Cylinder Yes Yes Yes No No No 4 Hydraulic Seal Hydraulic Yes Yes Yes No Yes No Cartridge-Plunger Cylinder Head 5 Sealing Head Sealing Head Yes Yes No Yes No No Cone Seal 6 HP Cylinder -- Yes Yes No Yes No No 7 Plunger -- Yes Yes Yes No Yes No 8 Hydraulic Piston -- Yes Yes Yes No No Yes

Note [1]:Remove/installed as a unit (HP Cylinder “Jug”)

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.2.5 Plunger and Hydraulic Cartridge Removal and Installation

1. Remove HP and LP piping/ hose, then remove HP cylinder jug following procedure 7.2.2 above.

2. Remove the proximity switch on the intensifier side nearest HP cylinder to be serviced. This procedure will allow hydraulic oil to drain to tank and will minimize oil spillage. Draining takes about 5 minutes. Remove cartridge retainer flange from hydraulic cylinder head by first removing retaining ring using a flat blade screwdriver. Wipe and clean surfaces, weep holes, and grooves in cartridge retainer flange. Check retainer flange for cracks.

3. Using cartridge/plunger removal tool threaded to the seal cartridge, pull the cartridge outward over the plunger. Seals in the hydraulic cartridge can be removed and replaced, or the entire cartridge can be replaced. It is recommended that at least one spare cartridge be kept on hand, ready to install. See Section 7.3.6 for servicing hydraulic seal cartridge.

4. With the cartridge removed, the plunger can be removed with the cylinder head in place. Slide the cartridge/plunger removal tool over the plunger, with the hex-shaped smaller end toward the plunger button. Note orientation of plunger button retainer pins (6 each), then align hex flats of tool with pins. Force tool by hand under pins, then rotate tool slightly to cause pins to retract enough to release plunger. Plunger can now be extracted from hydraulic piston. See Section 7.3.5 for servicing the plunger.

5. To install new plunger, slip cartridge/plunger removal tool over plunger, hex end toward plunger button, to help center plunger in cylinder head. Position plunger in mating pocket of piston, then force into place by hand. Using a , verify that all 6 pins are equally extended to grip plunger button.

6. Lubricate exposed surfaces of seals in hydraulic seal cartridge with food grade grease and slide cartridge over plunger into cylinder head cavity.

7. Thoroughly clean cartridge retainer flange, including cross-drilled weep holes. Install flange and internal retaining ring, making sure that the retaining ring seats fully inside its . Note that hydraulic cartridge O- rings may take up clearance. To install retaining ring, first tap lightly on retainer flange using plunger removal tool. This will compress cartridge O- rings enough to get retaining ring started in groove. Push on outer edge of retainer flange with a flat bladed screwdriver while working one end of retaining ring into groove. Retainer flange should tilt or tip enough to allow retaining ring to move into its groove. Continue working ring into groove while tilting flange until retaining ring is fully installed.

8. Install HP cylinder jug to hydraulic cylinder head per paragraph 7.2.2.

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.2.6 Hydraulic Cylinder Head and Piston—Removal / Re-Installation

1. Remove HP and LP piping/ hose, then remove HP cylinder jug following procedure 7.2.2 above.

2. Remove proximity switch (19) at cylinder end to be serviced. Loosen the remaining proximity switch to drain hydraulic oil in tank.

3. Remove hydraulic seal cartridge (8). Seal cartridge (8) removal is recommended to avoid sliding cylinder head (4) over plunger (2). The plunger need not be removed at this stage.

4. Loosen and remove 8 each socket head cap screws (18) retaining cylinder head (4) to hydraulic cylinder (15). The cylinder head and its O-ring (16) can be removed. The proximity switch mounting flats provide a small lip for loosening the cylinder head.

5. 5. To remove the hydraulic piston (21) from the hydraulic cylinder (15), remove one cylinder head, remove the proximity switch toward that end. On the opposite end remove the HP cylinder and end cap, then remove the retainer flange and hydraulic cartridge. The piston must be driven from the cylinder bore due to the seal squeeze and friction. Use a plastic head hammer to avoid striking the assembly with a metal object. See Section 7.3.7 for servicing the hydraulic piston.

6. Reassemble the hydraulic cylinder by reversing the above steps. Tighten 12M socket head capscrews (8 per cylinder head) in a crossing pattern to 190-210 N-m (140- 155 ft-lbs).

Remember to install and tighten proximity switches. CAUTION Failure to do so will result in considerable spraying of

hydraulic oil.

7. Install HP cylinder jug to hydraulic cylinder head per paragraph 7.2.2.

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SECTION 7 HIGH PRESSURE WATER SYSTEM

Item Description (1) Cylinder Head (2) Plunger (3) Hydraulic Cartridge, Plunger Seal (4) Bushing Retainer Flange (5) Retaining Ring (6) Hydraulic Cylinder (7) Plunger Removal Tool

Item Description (1) Sealing Head (2) Inlet Poppet (3) Gland Nut (5) Seal Head Spacer (6) Flange Ring (7) Suction Spring (9) End Flange (11) Retainer

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.3 Intensifier Subassemblies Inspection and Repair

The inspection and repair of the following subassemblies will be discussed: • Discharge HP Check Valve, Section 7.3.1 • Inlet Check Valve, Section 7.3.2 • Sealing Head, Section 7.3.3 • HP Cylinder, Section 7.3.4 • Plunger, Section 7.3.5 • Hydraulic Seal Cartridge, Section 7.3.6 • Hydraulic Piston, Section 7.3.7 • Hydraulic Cylinder, Section 7.3.8

7.3.1 Discharge HP Check Valve The HP discharge check valve can be serviced with the sealing head either installed in or removed from its intensifier HP cylinder. 1. Remove the gland nut from the sealing head using a pair of wrenches. 2. When the gland nut is removed, the spring guide and spring will normally stay in the gland nut. The poppet is removed by carefully dislodging it with a screwdriver. The seat is removed with a magnet. Inspect the seat for damage or cracking. A cracked seat should be replaced. The seat is symmetrical, and can be installed with either face toward the poppet. Note that a slight at the hole edge identifies the used side of the poppet seat. When reinstalling the seat, apply a thin film of High Purity Goop to both faces. Install the seat into the sealing head with the best surface facing the check poppet.

Item Description (1) Sealing Head (2)Poppet (3) Gland Nut (4) Poppet Seat (5) Spring (6) Guide Pin 01/2004 7 - 14

SECTION 7 HIGH PRESSURE WATER SYSTEM

3. Inspect the poppet, spring, and guide for wear. Replace the spring and guide if worn. 4. Apply a thin film of High Purity Goop to the sealing face of the gland nut. Install the guide, spring, and poppet into the gland nut. Apply a coating of food grade grease to the check poppet to hold it in place when installing gland nut in sealing head. 5. Apply High Purity Goop to the gland nut threads. Install the gland nut into the sealing head. The gland nut should be hand tightened until there is a gap of 5mm (0.20”) between the gland nut and sealing head. No threads should show. If the gap exceeds 5mm (0.20”), then the poppet has slipped out of place, and the parts must be removed, inspected and reassembled. 6. Using a crowfoot/torque wrench combination, torque the gland nut to 88 Nm (65 ft-lbs.). 7. Reconnect high pressure and low pressure piping, collar and quick disconnects per Section 7.2.1. Operate waterjet pump to verify HP fittings do not leak, and that the HP water signal is normal (indicative of normal check valve operation).

7.3.2 Inlet Check Valve 1. Use a ½” flat bladed screwdriver to unscrew the poppet retainer from the sealing head. The inlet check valve is disassembled. 2. Inspect and refinish the sealing head face seal surface per instructions in Section 7.3.3. 3. Inspect both surfaces of the flat washer shaped poppet. If one surface is marred, and the opposite surface is not, the poppet may be reversed with the best surface facing the sealing head. If both sides are worn, replace poppet. 4. Insure the poppet retainer threads, and the mating threads in the port sealing head are clean and dry. Install small O-ring over threads. 5. Assemble the inlet poppet, spring, and retainer to the sealing head using a ½” flat blade screwdriver. 6. Inspect the assembled unit to insure the following: • The poppet moves freely. • The spring is fully guided on the poppet retainer. • The spring end is 90° from the retainer’s screwdriver slot. • The poppet retainer is shouldered against the sealing head.

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SECTION 7 HIGH PRESSURE WATER SYSTEM

Item Description (1) Sealing Head (2) Inlet Poppet (3) Gland Nut (5) Seal Head Spacer (6) Flange Ring (7) Suction Spring (9) End Flange (11) Retainer

7.3.3 Sealing Head The sealing head should be inspected for scratches and wear on two surfaces: • HP cone ring seal contact surface • Inlet HP check valve poppet contact surface In addition, the sealing head inlet water groove should be examined for cracking. 1. Polish the cone ring 45 degree surface to achieve a smooth finish. Grooves or marks should be bearly discernable by fingernail test. 2. Inspect the inlet poppet sealing surface of the sealing head for pits, scratches, or jetting erosion. the seal head inlet poppet face is mandatory when rebuilding the sealing head. Using a piece of plate glass (not window glass) on a sturdy table, place a piece of 400 grit wet/dry sandpaper atop the plate of glass which provides the absolutely flat surface necessary for the polishing process. Using even, deliberate strokes, polish the sealing head until smooth. Rotate the head about 10-15 degrees every stroke. Be careful not to tilt or tip the head while polishing it as to not scrape the part. 3. When the sealing head is flat and smooth, perform a final polish with 600 grit wet/dry sandpaper. A finish is required. KMT Waterjet offers a refinishing service.

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.3.4 HP Cylinder 1. At a , use the seal removal tool to prevent scratching the cylinder bore sealing surface. Use a pulling action to remove the sealing head guiding ring. 2. Remove the bore liner. Use a plastic-faced hammer and the seal removal tool to drive out the plunger HP seal and follower. Be careful not to scratch the bore of the cylinder or damage the cylinder threads. 3. Clean sealing areas of HP cylinder inside diameter and inspect cylinder for rings, scratches, pits, residue build-up and other potential leak paths. Seal material or residue can build up a ring, and running a fingernail across it, will cause it to appear as a surface flaw. It is usually necessary to clean the area before performing an inspection. 4. Use 600 grit wet/dry sandpaper to polish HP cylinder inside diameter where the seal will locate. Polish only in a circumferential motion. Do not polish or drag the sandpaper along the length of the cylinder. Hold the sandpaper on the end of your finger, and move in a cylindrical wiping motion in the bore of the HP cylinder. Wipe residue from cylinder inside diameter and re- inspect for surface defects. NOTE The HP cylinder ends often show a “step” between inner and outer sleeves where the inner sleeve extends beyond the outer by a small amount. This is normal and does not indicate a flaw in the cylinder.

Item Description (1) Cylinder Body (5) Cylinder Head (2) Plunger (6) Liner (3) Plunger Seal Follower

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.3.5 Plunger Plunger surfaces can become streaked with longitudinal scratches or flaws, the surface can become discolored or dull in appearance, or the outboard end can become smeared with stainless steel due to contact with the bore liner. If any of these conditions become severe, the plunger HP seal and possibly the hydraulic seals will leak excessively. Repair of plunger surface flaws usually cannot be accomplished on site. KMT Waterjet Systems offers a plunger reconditioning service.

Item Description (1) Plunger Button (2) Plunger (3) Button

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.3.6 Hydraulic Piston The hydraulic piston contains a seal assembly, bearing rings, pins and flat spring bands, and check valves. Bearing rings (10) provide wear contact between piston and cylinder ID. (12) are held in place by 6 each pins (2) per plunger. Pins (2) are maintained in place by flat steel band (6). Check valves (4) are mounted internal to the piston to vent unwanted hydraulic pressure to the piston opposite side. These check valves prevent hydraulic pressure from building behind the plunger button

Replace Piston Seal 1. Remove bearing rings (10) and worn seal ring assembly (9).

Do not scratch bottom surface of piston seal groove. CAUTION Scratches to the seal groove sides and/or bottom can

result in a hydraulic leak.

NOTE: Use a smooth, dull-edged blade made from brass or similar soft (relative to steel) material to remove and install seal assemblies.

Item Description (1) Piston (2) Pin (12 ea) (3) (2 ea.) (4) Check Valve (2 ea.) (5) (6) Snap Ring (2 ea.) (7) Backup Ring (2 ea.) (8) O-ring (9) Seal Assembly (10) Bearing Ring (2 ea) (11) Set Screw (4 ea.) (12) Plunger (2 ea.) (13) O-ring (2 ea.)

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SECTION 7 HIGH PRESSURE WATER SYSTEM

2. With seal and bearings removed, inspect seal groove bottom for marks or scratches and residue buildup. Clean and /or repair groove surfaces as required. 3. Install replacement bearing rings (10). 4. Install replacement piston seal assembly (9). First install inner ring, taking care that this ring is not twisted after installation. Slide outer seal ring over metal edges, easing seal into place over inner ring. NOTE: Heating the piston seal ring in hot water (150 degree F for 3-5 minutes) increases seal flexibility.

Service Piston Plunger Sockets (2 each) 1. Remove flat spring bands (6) and remove plunger retainer pins (2). Inspect pins and spring band for deformation or unusual wear. Clean and inspect pin holes in piston for unusual wear or hole deformation/ enlargement. 2. Remove plunger button O-ring (8) and backup ring (7) (2 places), taking care not to scratch or otherwise damage seal groove surfaces. Clean and inspect seal grooves for residue buildup or surface marks that might cause seal leaks. 3. Inspect plunger button sockets for unusual wear. NOTE: Plungers may make an indentation in the bottom of the plunger socket. The bottom of this socket may show the impression of the plunger on it due to the high contact forces between piston and plunger. This compression mark is normal.

Service Piston Internal Check Valves NOTE: Check valve (4) servicing is not necessary unless there is suspicion of a problem. If the check valves (2 each) or piston internal passages must be serviced, seal and pin servicing is also recommended.

1. Check valves (items (4), 2 each) or cross- plug (11) removal may be necessary. Re-install using thread locking compound applied sparingly on the plug threads.

CAUTION Excess compound may clog a check valve or block a drilled passageway.

NOTE: To avoid excess compound, position the plug or retainer on its Allen wrench, apply thread locking compound, then hold the plug/retainer horizontal on a towel while rotating the plug/retainer to wipe off excess thread locking compound.

2. Install O-ring in check valve cavity, positioning in hole bottom with - like blunt instrument. Install check valve with chamfered end toward O- ring. Coat retainer (3) with thread locking compound. Then thread retainer 01/2004 7 - 20

SECTION 7 HIGH PRESSURE WATER SYSTEM

(3) over check valve cartridge (4). Allow 24 hours for thread locking compound to set. 3. Install plugs (11) in cross- drilled passages by applying thread locking compound to plug threads. Then thread plugs (2 each per hole), with the second plug acting to lock in the first. Allow 24 hours for thread locking compound to set. Install Plunger Button Seals and Retainer Pins in Hydraulic Piston 1. Install new backup ring (7) and O-ring (8) in each internal groove in each plunger pocket (2 places).

CAUTION Failure to install backup ring can result in plunger being forced out of plunger pocket.

2. Reinstall pins in piston, verifying that each pin moves freely without excess side play in its cavity. 3. Reinstall band (6) over pins. Repeat this process for the opposite piston side. With piston on bench, install plunger in each end of piston, checking snap-in feature of plunger attachment. Use plunger removal tool to verify that pins retract (release plunger) and close (retain plunger) in a uniform manner.

Install Hydraulic Piston Assy into Hydraulic Cylinder NOTE: Piston seal assembly must be compressed before the piston assembly will slide into the hydraulic cylinder. A ring compression tool such as shown in the figure below is recommended. 1. Check that hydraulic cylinder bore is free grit, or contamination, and that the proximity switches are removed to prevent interference. Lubricate piston bearing and seal surfaces with FML-2 grease. Lightly lubricate 2-3 inches of cylinder (15) bore with same grease. 2. Fit or drive piston assembly into ring compression tool (20). Position compression tool with piston assembly over end of hydraulic cylinder. Using a plastic- faced hammer so as not to damage piston surfaces, gently drive the piston assembly into the hydraulic cylinder. 3. Remove seal compression tool, continue driving piston assembly into hydraulic cylinder until it is between the proximity switch holes. Continue intensifier re- assembly by installing cylinder heads, plungers, hydraulic seal cartridges, and HP components.

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SECTION 7 HIGH PRESSURE WATER SYSTEM

(15) Hydraulic Cylinder (19) Proximity Switch (20) Seal Ring Compression Tool (P460) (21)Hydraulic Piston Assy

7.3.7 Hydraulic Cylinder The inside diameter surface of the hydraulic cylinder should be inspected for wear grooves and surface finish whenever the hydraulic cylinder heads are removed. Excessive grooving on this bore is indicative of piston seal wear.

Item Description (1) Hydraulic Cylinder (2) Cylinder Head (3) Proximity Switch (5) Cap Screw (8) Back-up ring (9) O-ring (10) Spacer

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SECTION 7 HIGH PRESSURE WATER SYSTEM

7.4 HP Dump Valve

The dump valve assembly includes a normally open HP water valve, plus a solenoid operated air valve for the air actuator on the dump valve. Replacement parts for the HP valve are provided in the Parts Lists (Section 12, see Figure 12- 7, “Bulkhead Piping Assy”).

7.5 HP Attenuator There is no servicing of the HP attenuator at the customer level. The seals in the HP attenuator are tested at KMT Waterjet to high pressure in excess of operating pressure making disassembly difficult. In the event of a HP water leak of a HP attenuator, the attenuator should be replaced. The defective attenuator should be returned to KMT Waterjet Systems for replacement or servicing.

01/2004 7 - 23

SECTION 8 ELECTRICAL SYSTEM

Section 8 ELECTRICAL SYSTEM

8 ELECTRICAL SYSTEM - Features (8) The electrical system contains all functions necessary for turnkey operation. This includes the control and starter panel, intensifier reversal circuit. The electrical enclosure, buttons, lights, and electrical harnesses into and out of this enclosure can be exposed to occasional water spray and dust per NEMA-12 standards.

8.1 Electrical Overview There is only one electric motor on the SL-IV Waterjet Pump. The control voltage of 24vdc is furnished by the built-in power supply drawing its power from the motor’s AC circuit.

8.1.1 Motor Starter Circuit Two motor starter circuits are offered as built- in assemblies for the SL-IV 30hp and 50 hp Waterjet Pumps: • Wye- delta starter, commonly used in Europe to reduce current surges during motor startup, and • Across- the- line starter, commonly used in North America, which is a simpler circuit.

Other features included in the motor starter circuits include:

• Manual disconnect with door handle interlock • Overcurrent protection • Hydraulic unloading during startup, allowing the motor to reach full speed • Motor terminal block for European models

8.1.2 Control Circuits and Logic The operator controls the waterjet pump primarily through the digital display panel. The digital interface (display) communicates with the PLC controller located inside the electrical enclosure. In order to prevent costly damage to the pump, automatic shutdown logic and diagnostic messages are displayed to the operator as to the cause of the impending shutdown. The inputs that trigger automatic shutdown are:

• Motor Overload • Motor Feedback Failure • Oil Level Low • Oil Temp High • Low Booster Pressure • Low Inlet Water Pressure • Long Idle Time Shutdown • Booster Temp High • Left Overstroke Shutdown • Right Overstroke Shutdown • T/W Overstroke Shutdown

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SECTION 8 ELECTRICAL SYSTEM

For more information on these conditions and recovery procedures, refer to Section 3, Operation, of this manual. A circular connector in the side of the enclosure is provided in order to interface with the remote operator’s station • Start • Stop • Emergency Stop (E-Stop) • Pump RUN indicator light • Pump malfunction light • Remote 2-pressure • Proportional Pressure (optional)

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SECTION 8 ELECTRICAL SYSTEM

8.1.3 Operation To energize the Control Panel, pull the EMERGENCY STOP button, then press the RESET button. The Control Panel will display the RUN screen. After a five second delay, if all run conditions are met (no alarm conditions, and inlet water pressure above 30 psi) the RUN BAR will flash, indicating machine is ready to start.

Item Description 1 Electrical Harness, Sensor/ Control 2 Cable, Cutting Water Supply Solenoid 3 HP Shutoff (Dump) Valve 4 Cable (2 ea), Directional Control Valve 5 Cable, HI/LO Pressure Solenoid 6 Cable, Proximity Switch Sensor- Single Intensifier 7 Cable, Proximity Switch Sensor- Redundant Intensifier 8 Motor Electrical Hookup 9 Cable, Hot Booster Pump Temperature Sensor 10 Electric Motor 11 Cutting Water Inlet Shutoff Valve 12 HP Dump Valve (Air Solenoid) 13 Low Oil Level Sensor (Reservoir- Mounted) 14 High Oil Temperature Sensor (Reservoir- Mounted) 16 Proximity Limit Switch 17 Directional Control Valve 18 Booster Pump Before starting intensifier insure all parameters are set to users specifications.

On RUN screen press PRESSURE button to set final pressure. The arrow below the PRESSURE switch indicates final pressure. The pump will be held in low

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SECTION 8 ELECTRICAL SYSTEM

pressure for 20 seconds after motor is started, after which pressure will go to high if high is selected, otherwise the pump will stay in low pressure. The final pressure may also be set on the PRESSURE CONTROL screen if analog control is present.

On MAIN MENU scroll to % CAPACITY screen and insure the correct intensifier is set – either intensifier one or two, by pressing the SELECT INT 1 / 2 button.

On the % CAPACITY screen set the SHUTDOWN %. Press UP and DOWN arrows to increment or decrement OVERSTROKE SETPOINT or OVERSTROKE SHUTDOWN. Because overstroke protection is related to stroke speed under actual pressure setting, this allows you to control sensitivity of the overstroke protection software for your particular operating pressure.

Return to the MAIN MENU. Scroll to SET-UP screen. There are two SET-UP SCREENS – If analog pressure control is not installed on the machine, a screen will appear that does not include the TRANSDUCER and PROPORTIONAL SELECT buttons. These buttons are used only if a pressure transducer and/or a proportional valve are installed on the machine. Set water reset function and idle shutdown function on or off. WATER RESET FUNCTION Press on (I) to shut water off five (5) minutes after machine shuts down. Selecting this function will insure that the inlet cutting water is shut off following a shutdown fault. This can prevent water from leaking past a damaged water seal following an overstroke shutdown caused by a seal failure. IDLE SHUTDOWN FUNCTION Press on (I) to stop machine after 30 minutes of inactivity (machine not stroking). This feature saves energy by automatically shutting down the intensifier if it is not being used. For more information, refer to Section 3, Operation, of this manual.

(1) Standard machine, start-up after machine has been E-stopped: Safety dump valve will be open. It will close 3 seconds after the T/W begins stroking. The pump will be held in low pressure for 20 seconds after motor is started after which pressure will go to high if high is selected, otherwise will stay in low. The purpose for this is to allow entrapped air to be bled from any HP cylinder that has been maintained to avoid hot air burning the plunger seals.

(2) Standard machine, start up after normal stop: Safety dump valve will be closed, pump will be held in low pressure for 20 seconds after motor is started, after which the pressure will go to high if high is selected, otherwise will stay in low.

(3) Machine equipped with hp transducer, start up after E-stop: same as (1) above.

(4) Machine equipped with hp transducer, start up after normal stop: If pressure is allowed to bleed through orifice to below 1000 psi, dump valve

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SECTION 8 ELECTRICAL SYSTEM

will open and start up will be like (1) above, if pressure is not allowed to bleed, start up will be as (2) above.

The display screen will always default to the Run screen after being on any other screen more than 5 minutes. NOTE: The high-pressure dump valve will not close if the air supply is OFF. After pressing the Start button:

The motor starter in the control panel is activated and the motor starts.

The intensifier assembly starts operating. Reversal position is sensed by proximity switches, which send signals to the PLC inside the control panel. The PLC activates the opposite solenoid on the pump reversing valve. After pressing the START Pushbutton: • The unloading valve delays hydraulic pressure build-up while the motor starter circuit accelerates the motor to normal rotating speed. • The intensifier assembly starts operating. Reversal position is sensed by proximity switches, which send signals to the relay logic inside the control panel. The relay logic activates the opposite solenoid on the directional control valve.

8.2 Maintenance Overview Electrical components require minimum attention and service. The components that require service are the proximity switches on the intensifier assembly, and the optical relay switch in the control panel.

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SECTION 8 ELECTRICAL SYSTEM

8.2.1 Proximity Switch Service If the pump quits pumping water, the proximity switch may need to be replaced. Check the LED lights on the switch. Symptoms of a failed proximity switch are (1) the LED lights do not change state (indicating not sensing the piston) or (2) the LED lights are continuously flashing. Replace the switch when failure occurs.

Components: (1) Intensifier Assembly (2) Electrical Harness (3) Proximity Switch (4) Hydraulic Cylinder

Recommended Tools: • Allen (hex) Wrench, M5 • Torque Wrench • Rags

Parts: • Proximity Switch

Replace Proximity Switch 1. Turn off waterjet pump, disconnect and LOCKOUT electric power. 2. Disconnect cable. 3. Unscrew bolts, remove proximity switch. 4. Install new switch. Install bolts. 5. Torque bolts to 16-18 Nm (140-160 in-lbs.).

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SECTION 8 ELECTRICAL SYSTEM

8.2.2 Optical Relay Switch Service

Components: Optical Relay Switch Recommended Tools: Flat screwdriver, 3mm (1/8 inch) Parts: Optical Relay

Replace Optical Relay Switch 1. Turn off waterjet pump, disconnect and LOCKOUT electric power. 2. Open control panel. 3. Unscrew optical relay switch mounting bolts, remove and replace. If the motor will not start and a “motor feedback” fault message appears, the optical relay which controls the motor starter may need replaced.

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SECTION 9 HYDRAULIC SYSTEM

Section 9 HYDRAULIC SYSTEM

9 HYDRAULIC SYSTEM - Features (9)

In addition to “slow start”, other features of the hydraulic system are listed below:

• Hydraulic 4-way valve – directional control valve (DCV)–solenoid–operated. Used for HP cylinder shifting. • Close - coupled motor/hydraulic pump – pump mounts directly to the motor, saving approximately 8-10 inches of length on the overall pump/motor assembly, reducing footprint of the waterjet pump package. The pump is directly coupled to the motor rather than a conventional standalone housing and shaft coupling assembly. • Reference hydraulic gage – used for adjusting pressures in the HI/LO relief valves. Displays hydraulic pressure, as well as water pressure in multiple units directly at the pressure adjustment knob. • Built in hydraulic oil drip pan – allows for the spills to be contained within the machine while addressing environmental issues of mixing water and oil. • Remote dual pressure control – allows for flexibility at the cutting nozzle in pressure adjustments for certain pure water/abrasive applications. • Pressure adjustment control – allows for infinite pressure settings though out the entire pressure range for flexibility.

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SECTION 9 HYDRAULIC SYSTEM

9.1.1 Components Following are the hydraulic system components:

NOTE: The main pump is direct-mounted to the motor. The main pump control includes hi and lo preset pressures. The operator is able to switch between pressures at the operator’s console.

Item Description (1) HI pressure control (2) LO pressure control (3) Fixed relief valve (4) Gage (5) Manifold (6) Pump (7) Motor (8) Directional Control Valve (9) Hydraulic Cylinder (10) Hi-Lo Solenoid Valve

9.2 Operation

The hydraulic system operates at HI or LO pressure settings up to the maximum flow capacity of the variable displacement piston pump. Upon selecting HI or LO, the operator is able to adjust the HI or LO pressure controls within the respective adjustment ranges. The electric motor (7) drives the variable displacement, pressure compensated pump (6). The hydraulic manifold (5) is mounted on the pump discharge. The flow from the pump passes through check valve to the directional control valve (8), and the directional control valve sends the flow to the hydraulic cylinders (9) in one direction until the piston activates the proximity switch at the end of the 01/2004 9 - 2

SECTION 9 HYDRAULIC SYSTEM

stroke. The activated proximity switch sends an electrical signal to the programmable controller (PLC). This PLC in turn activates the directional control valve (8) to change flow and to reverse direction of movement of piston until activating the opposite end-of-stroke proximity switch. Although one DCV supplies hydraulic power to two intensifier hydraulic cylinders arranged in parallel, these cylinders operate at approximately the same cycle rate due to logic built into the PLC (see Section 8, Electrical System).

9.2.1 Hydraulic Pressure Adjustment

A variable displacement pressure compensated feature maintains constant operating pressures even under variable flow demands. Dual pressure control is standard. Switching high to low pressure may be done at the control panel (or remotely) with the HI-LO switch that activates the solenoid valve (11). The HI pressure is set by adjusting the knob and the LO pressure is adjusted using a wrench on that relief cartridge (2). Turning the knob/adjusting the screw clockwise increases pressure.

NOTE: In order to remote select the pressure, the HI-LO switch should be set to the “HI” position.

9.2.2 Hydraulic System Pressure Protection

Besides the HI-LOW Pressure Control Valves, the hydraulic system pressure is limited by the main relief valve (3). The operating hydraulic pressure is indicated by hydraulic gage (4). Control Valve Pressure Adjustment Hyd. Pressure bar (psi) Increase Decrease Maximum Minimum High Pressure 1 Clockwise Counterclockwise 207 (3,000) 1.7 (25) (HI) Low Pressure 2 Clockwise Counterclockwise 103 (1,500) 1.7 (25) (LO) Main Relief 3 Fixed Fixed 234 (3,400)

NOTE: Do not adjust the HI pressure control to pressures greater than 3,000 psi. Doing so will cause the main relief to open limiting hydraulic pressure to 3,400 psi. Also excessive opening of the main relief valve will result in significant wasted heating of the hydraulic oil, and a decrease of HP water flow performance.

9.3 Motor / Hydraulic Service Maintenance The hydraulic oil filter should be checked daily and replaced when the visual indicator is in the red zone. The hydraulic oil should be replaced every 3000 hours or yearly, whichever occurs first. For hydraulic oil and filter maintenance, see Section 10, Recirculation System. The hydraulic system components that require periodic maintenance are the motor and the manifold. The motor needs to be serviced every 5000 hours of

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SECTION 9 HYDRAULIC SYSTEM

use. The operating pressure settings of the manifold need to be checked daily and adjusted if necessary.

Recommended Tools: Manual Open End Wrench 14mm (9/16”) Rags Parts: Bearing Grease, SRI #2 or equivalent

Item Description (1) Motor (2) Manifold (3) Recirculation Pump (4) Hydraulic Pump

9.3.1 Motor Service

1. Locate the two zerk fittings, they are located at each end of the motor, remove their plastic caps. 2. Apply one or two strokes of grease. Replace caps on zerk fittings. 3. Run motor a few minutes.

9.3.2 Manifold Service

1. Check operating pressure. 2. If pressure adjustment is necessary: 3. Adjust high pressure control valve. Turn locking nut counterclockwise, then turn the knob clockwise to increase pressure, counterclockwise to decrease. 4. Adjust low pressure control valve. Turn locking nut counterclockwise with open-end wrench. Turn the hex clockwise to increase pressure, and counterclockwise to decrease. Lock in place with nut.

01/2004 9 - 4

SECTION 9 HYDRAULIC SYSTEM

9.3.3 Motor/ Pump Coupling – Spline Lubrication—

(Recommended Annual Service Procedure)

• Special Tools and Supplies: • Optimal Spline Lubricant- (IR P/N 10184802) • Cleaning Solvent • Miscellaneous Wooden Blocks • Shop Rags • Spare Shaft Seal—(See Table Below) Shaft Seal Part No’s -- Hydraulic Pumps Model/ kW Piston Pump Displacement (cc’s/rev) SHAFT SEAL – IRWJ PARTNO. 45 05096011 SL IV 30 / PLUS SL IV 50 / PLUS 71 05088083 SL IV 100 140 49831159 1. Lock out electrical power to prevent inadvertent motor start 2. Unbolt motor vibration mounts from frame base plate (4 ea socket head cap screws). 3. Support hydraulic pump assembly while leaving all hose connections undisturbed. Use wooden blocks to support pump/ manifold assembly. 4. Remove bolts attaching piston main pump to electric motor. 5. Slide electric motor away from hydraulic pump package, revealing spline coupling.

NOTE: Additional clearance and access to the motor and pump splines can be had by pushing the pump assembly to the right. The main pump suction hose will limit movement to approximately 1-inch. It should not be necessary to disconnect any hydraulic hoses for this procedure.

NOTE: If additional clearance is required to separate motor and pump, unbolt electrical panel from IR Waterjet pump frame (SL-IV30/PLUS, SL-IV50/PLUS SL-IV100). Remove 4 ea ½-in. nuts from studs holding electrical panel to end of frame. Move electrical panel 4-8 inches away from frame. Disconnecting of motor lead wires should not be necessary to perform this procedure. Note that wire ties holding the electrical control harness to the top pan should be removed to allow the electrical control panel.

6. Wipe residue from motor internal spline and from male pump splines. Avoid damage to shaft seal on hydraulic pump. 7. Inspect splines for unusual wear. Consult with IR Service if spline wear appears beyond limits.

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SECTION 9 HYDRAULIC SYSTEM

8. Note presence of hydraulic oil or evidence of hydraulic leak in shaft cavity. If hydraulic leak is indicated, replace shaft seal. 9. Lubricate internal and male spline wear surfaces with Optimal grease. Cover mating spline surfaces sufficient to assure all metal- to- metal contact surfaces are lubricated. 10. Move motor and pump assembly together to re-engage splines. Install hex head cap screws through holes/slots in pump flange into motor face. 11. Reinstall motor mount socket head capscrews (4 ea). 12. Reinstall electrical panel to end of frame (if applicable). 13. Start motor, apply full HP water pressure, noting any unusual sounds from motor / pump assembly. 14. (Spline lube procedure complete)

01/2004 9 - 6

SECTION 10 RECIRCULATION SYSTEM

Section 10 RECIRCULATION SYSTEM

10 RECIRCULATION SYSTEM - Features (10)

The recirculation system keeps the hydraulic oil at operating temperature while using the minimum amount of cooling water flow. The system also provides the necessary oil conditioning and filtration to maintain oil cleanliness. The conditioning of the hydraulic oil includes cooling it, cleaning it, and together with the hydraulic tank, removing air bubbles entrained in the oil due to agitation and turbulent flow in the main pump circuit.

10.1 Components

The cooling and filtration system (recirculation system) is equipped with the following: • Recirculation pump (gear-type)–which receives oil from the hydraulic reservoir • Heat exchanger - cooling water is controlled by the water modulating valve • Oil filter assembly - includes an indicator to show the filter element condition. It also includes a bypass or relief valve, should the filter element be allowed to become entirely clogged with dirt/contaminants.

10.2 Operation

The recirculation pump (1) takes oil from the tank (6) and pumps it to the oil to water heat exchanger (3), then to the oil filter (5) and back to the tank. The visual indicator (4) indicates when the filter element needs replacement. It should be read when both the water jet pump is running and the oil temperature is approximately 46°C/115°F. If the indicator shows yellow or just started into the red zone, then it is time to change the filter element. Oil fill port must be used when pumping oil into tank to assure cleanliness. By filling at this point, the hydraulic oil must pass through the hydraulic filter to get to the hydraulic tank, guaranteeing that the oil into the tank gets at least one pass through a good filter.

Operating Temperature Adjustment The operating temperature is adjusted by turning the water modulating valve (19) adjusting knob with a flat blade screwdriver. Clockwise increases the oil temperature. The water modulating valve regulates the cooling flow that enters the heat exchanger (6) and then discharges to the drain. The operating oil temperature is factory set at 46°C (115°F) based on the temperature and flow of cooling water at the factory. Field adjustment may be necessary.

01/2004 10 - 1

SECTION 10 RECIRCULATION SYSTEM

Item Description (1) Recirculation Pump (2) Water Modulating Valve (3) Heat Exchanger (4) Pressure Gage (5) Oil Filter (6) Oil Fill Port (7) Oil Fill (8) Hydraulic Oil Tank

Operating Temperature Adjustment The operating temperature is adjusted by turning the water modulating valve (2) adjusting knob with a flat blade screwdriver. Clockwise increases the oil temperature. The water modulating valve regulates the cooling flow that enters at port “D” to the heat exchanger (3) and then discharges through port “C” to the drain. The operating oil temperature is factory set at 46°C (115°F) based on the temperature and flow of cooling water at the factory. Field adjustment may be necessary.

10.3 System Pressure Protection System pressurization over 4.2 bar (60 psi) is prevented by relief valve (8) located on filter head (5). Adjustment Setting Control Valve Increase Decrease Maximum Minimum Oil Temperature 2 Clockwise Counter- 52oC 41oC clockwise (1250 F) (1100F) Oil Pressure 8 Fixed Fixed 4.2 bar 3.8 bar (60 psi) (55 psi)

01/2004 10 - 2

SECTION 10 RECIRCULATION SYSTEM

10.4 Maintenance Overview

During normal operating condition, the oil will be maintained at the correct operating temperature and the visual indicator will read in the green zone. In order to get the best value from the hydraulic system (including the recirculation system) one should change the filter element when it indicates that it is time. The hydraulic oil should be changed after 3,000 hours or 1 year of service (whichever comes first) or whenever a fluid sample indicates that it is contaminated and beyond being fixed by simply operating the filter. Parts: Hydraulic Oil: General service, use Mobil #DTE Heavy Medium, No. 60016-3 (KMT part 05022702) Food service, use Conoco AA-20 (KMT part 49835762) Oil with additives such as zinc diophosphate for antiwear are not recommended because of reaction with water.

Tools: Open End Wrench, 1-1/4” Rags Container to collect oil Oil filter/ transfer pump with ¾” hoses. Inlet hose with ½” male pipe connector, and pump discharge hose with ¾” female JIC connector.

Oil Filter If the visual indicator (slide bar) is in the yellow zone or entering the red zone, this is an indication that the oil filter needs to be replaced. Components: (1) Oil Filter Head (2) Element (3) Pressure Gage Parts: Element Tools: Filter Wrench Rags Container to collect oil spills

Replace Oil Filter 1. Unscrew element from filter head with the filter wrench. 2. Oil gasket of new element. 3. Screw new element on head. 4. Start pump and check for leaks.

01/2004 10 - 3

SECTION 10 RECIRCULATION SYSTEM

Oil Reservoir The oil reservoir is equipped with the following: • Visual temperature and level indicator • Air breather and filter that prevents dirt from being sucked into the reservoir whenever the oil level drops, then allows air to escape when the level rises • Drain valve, and • Fill components. The fill components consists of the Oil Filter Head, Fill Port, and the Fill Port Cap.

WARNING The breather is not a fill component, and must not be used as a fill point.

After 3,000 hours of operation, or yearly (whichever happens first), analyze the hydraulic oil and replace if necessary.

01/2004 10 - 4

SECTION 10 RECIRCULATION SYSTEM

Item Description (1) Filter Assembly (2) Oil Fill Port (3) Temperature Sensor (4) Oil Fill Port Cap (5) Oil Tank Cover (6) Shut-Off Valve (7) Breather

Replace Hydraulic Oil 1. Drain the reservoir, by connecting the inlet hose of the oil filter/ transfer pump to the drain valve. Open valve and pump oil to container. 2. Close hand valve, remove oil filter/ transfer pump inlet hose from hand valve. NOTE Never assume a new of oil is free of damaging contaminants. Typically, oil from a new drum does not meet the hydraulic system cleanliness requirements. For this reason it is important to use the oil filter/ transfer pump, which forces oil through the return filter into the reservoir.

3. Remove cap from fill port. 4. Connect oil filter/ transfer pump discharge to fill port. This will assure clean filtered oil is pumped into the reservoir. Oil must be filtered through an equivalent filter such as a 10 micron filter element or see filter element in figure CAUTION 12 in section 12. Failure to do so will cause damage to the primary hydraulic components, voiding the

warranty. 01/2004 10 - 5

SECTION 10 RECIRCULATION SYSTEM

5. Check oil sight gage to assure proper fill level. Remove hose, cap fill port. 6. Remove the plug of the main hydraulic pump case and make sure the case fills with oil. With the plug removed, head pressure from the reservoir will force oil into the pump case. 7. Run pump following initial start-up procedure. This will assure the system is filled. 8. Check oil sight gage. Add oil if necessary. 9. Disconnect oil filter/ transfer pump discharge hose, install fill port cap.

CAUTION Failure to fill the pump case with oil will damage the pump due to air becoming trapped inside.

01/2004 10 - 6

SECTION 11 SPECIFICATIONS

Section 11 SPECIFICATIONS

11 Specifications (11)

Following are the specifications for the Waterjet Pump. Included are the specifications for the equipment, torque, cutting water, cooling water, and the maximum quantity of orifices that can be supported.

11.1 Equipment Specifications

SL-IV Waterjet Pump Size 37 (50) kW (hp) Installation location Indoors -Air borne dust/contaminants Minimal Ambient temperature -Minimum storage 2(36) °C(°F) -Minimum operating 5(40) °C(°F) -Maximum operating 40(104) °C(°F) (see note [1]) Maximum Relative Humidity (see note [2]) -At Maximum Operating Temp. 95% Electrical (see note [3]) -Motor type TEFC (see note [4]) Voltage / Service Amps 200/3/50 150 Volts/Phase/Hertz/Amps 208/3/60 144 240/3/60 130 400/3/50 75 415/3/50 72 480/3/60 65 575/3/60 52 Sound Level 75.5 dB(A) Controls -Voltage 24 volts, DC -Power Supply 10 amps, DC -Safety shutdown switch settings High oil temperature 62 (144) °C (°F) Low oil level 80 (21) liters (gal). Booster Pump Overheat 106 (28) °C (°F) (see note [5]) Hydraulic System -Oil tank capacity 53(14) liters (gal) -Recommended oil type Mobil, DTE Heavy Medium, # 60016-3 (IR # Regular applications 05022702) Food applications AMOCO #FG68EL (IR # 49835762) -Hydraulic oil operation Minimum temperature 15(60) °C(°F) Maximum temperature 65(150) °C(°F) Note [1]: Based on motor nameplate data, oil temperature must be maintained within operating specifications. [2]: When relative humidity is above 50%, frequently check oil in tank for water content. [3]: Not all motor voltages are readily available, check with factory for availability. [4]: Totally enclosed fan cooled. (5): Sound level per TUV report DE1-I-9047401

01/2004 11 - 1

SECTION 11 SPECIFICATIONS

SL-IV Waterjet Pump Size 37(50) kW (hp) Optimum temperature 46(115) °C(°F) Hot oil shutdown 62(144) °C(°F) Beta 10 >/= Fluid Filtration Rating Note [6] 100 Fluid Cleanliness Level 17/14 Note [7] -Hydraulic Pump Type Piston Displacement Variable Pressure Compensated Flow rate 65(17) l/min(gpm) -Hydraulic Settings (factory) Main Relief Valve 206 (3000) bar (psi) Note [8] -Hydraulic oil cooling Total heat rejection 7.4 (10) kW (hp) Cooling fluid requirements at inlet fluid temperature 18 (65) °C (°F) Maximum cooling flow 9.46 (2.5) l/min (gpm) Maximum inlet pressure 6.9(100) bar (psi) Pressure drop 2 (30) bar (psi) Cutting Water "IN" -Minimum inlet pressure 2.4(35) bar (psi) -Maximum inlet pressure 5 (73) bar (psi) Important: inlet pressure must be constant. -Maximum outlet pressure 8.3 (120) bar (psi) -Maximum inlet temperature 29 (85) °C (°F) -Optimum inlet temperature 18 (65) °C (°F) -Factory Booster Pump Settings Inlet Pressure 4 (58) bar (psi) Outlet Pressure Set at 8.3(120) bar (psi) (see Note [8]) Cutting Water Out -Maximum flow rate 3.8(1.0) l/min(gpm) (Note: Specifications listed below apply equally to 30 hp and 50 hp models) -Maximum allowable pressure 4,100 (60,000) bar (psi) Compressed Air -Flow rate maximum 0.028 (1.0) m3/min(cfm) -Inlet pressure range 5-6 (75-85) bar (psi) Service Connections -Cutting water in 1/2" NPT -Cutting water out 9/16" 60,000 psi HP fitting -Cooling water in 1/2" NPT -Cooling water out 1/2" NPT -Plant air in 1/4" NPT -Cutting water drain 1/2" NPT -Oil tank drain valve 1/2" NPT -Oil tank fill port ¾" male JIC Note [6]: Beta filtration rating—There are 100 particles per ml larger than 10 microns upstream of the filter for each particle (per ml) greater than 10 microns downstream of the filter. Note [7]: ISO-4406 fluid cleanliness ratings—17 ~ < 1,300 particles per ml > 25 microns // 14 ~ < 160 particles per ml > 15 microns. Note [8]: Booster pump discharge pressure is dependent on inlet pressure.

01/2004 11 - 2

SECTION 11 SPECIFICATIONS

11.2 Torque Specifications

Recommended Torque Values–Hydraulic Intensifier and HP Connections

Do not exceed torque values, excess torque can cause WARNING component damage or failure with potential hazards to

equipment and personnel.

Item Torque Nm (ft-lb) Wrench mm (inch) Hydraulic Intensifier Hydraulic Cylinder - End bell bolt 200(145) M12 hex - Proximity switch 17(13) M5 hex - Cylinder Flange Nut 275 (200) 1-7/16 hex Seal Head - Gland Nut 176(130) 30 (1-3/16) Crowfoot - HP Tubing Nut 67(50) (13/16) Crowfoot Pneumatic Valve - 3/8" Inlet 67(50) (13/16) Crowfoot 1/4" Outlet 34(25) (5/8) Crowfoot H P Fitting Gland Nuts - 1/4" Nut 34(25) (5/8) Crowfoot - 3/8" Nut 67(50) (13/16) Crowfoot - 9/16" Nut 149(110) (1-3/16) Crowfoot

NOTE Measurements are made with lubricated components and a calibrated torque wrench. Inconsistencies in wrench settings, lubrication, and technique, may not produce a leak tight seal. If leakage persists, increase the torque until the components seal, do not exceed a value 15% greater than shown. If leakage persists there is a component problem. EXCESSIVE TORQUE MAY DAMAGE OR REDUCE THE LIFE OF COMPONENTS. Use of an antiseize thread lubricant, like High Purity Goop (IR P/N 49864887) is highly recommended for tightening of stainless steel HP water fittings. A torque wrench kit is available from KMT Waterjet. (KMT P/N 49895436).

01/2004 11 - 3

SECTION 11 SPECIFICATIONS

11.3 Cutting Water Specifications

The cutting water supply to the waterjet pump must meet the following specifications. High concentration of dissolved solids, especially calcium, silica, and chlorides, will affect high pressure component life. A water analysis will indicate the type of water treatment necessary.

Minimum Water Quality Parameters Better Best Requirement Alkalinity (mg/l) 50 25 10 Calcium (mg/l) 25 5 0.5 Carbon Dioxide (mg/l) 0 0 0 Chloride as Cl (mg/l) 15 1 0,1 Free Chlorine (mg/l) 0,05 0,05 0.05 Iron as Fe (mg/l) 0.2 0.1 0.01 Manganese as Mn (mg/l) 0.1 0.1 0.1 Magnesium as Mg (mg/l) 0.5 0.1 0.1 Nitrate (mg/l) 25 25 10 Oxygen (mg/l) 2 1 0.1 pH Value 6.5 - 8.5 6.5 - 8.5 6.5 - 8.5 Silica (mg/l) 15 10 1 Sodium (mg/l) 50 10 1 Sulfate (mg/l) 25 25 1 Total Dissolved Solids (mg/l) 200 100 25* Electrical Conductivity 290 145 45* [µS/cm] Total Hardness as CaCO3 25 15 1 (mg/l) Turbidity (NTU) 5 5 1 * Do not reduce beyond this amount or the water will become too aggressive.

Cooling Water Specifications Depending on the type of cooling system (closed recirculation, once through, etc.), the following common problems can be experienced:

Closed recirculation: Corrosion Fouling

Once through: Corrosion Fouling Scale Microbiological Scale control is the most common problem, and is the result of insoluble matter deposited on the heat transfer surface. Calcium carbonate is the primary cause of scale when calcium bicarbonate breaks down. As the temperature of the water increases it becomes less able to hold carbonates in suspension. To predict the tendency of scale formation, the Langelier's saturation index can be used as a guide:

01/2004 11 - 4

SECTION 11 SPECIFICATIONS

Saturation Index = pH-pHs where pHs is calculated at saturation with calcium carbonate. A positive index indicates a tendency to deposit calcium carbonate, the higher the positive value, the higher the scale formation. A zero index corresponds to water that is in equilibrium with respect to calcium carbonate.

Orifice Support Capacity The SL-IV Waterjet Pump supplies high pressure (HP) water up to 3,800 bar (55,000 psi). The following table shows size, ratings, and maximum quantity of orifices that can be supported. Orifice Rated power Pressure Flow Qty Diameter kW(hp) Bar (Psi) lpm (gpm) mm (inch) 1 0.33 (0.013) 1 0.28 (0.011) 37 (50) 4,100 (60,000) 3.4 (0.9) 1 0.25 (0.010) 3 0.17 (0.007) 6 0.12 (0.005)

01/2004 11 - 5

SECTION 12 PARTS LIST

Section 12 PARTS LIST

12 Spare Parts Catalogue (12)

STREAMLINE SL-IV 50 (PLUS) High Pressure Waterjet Pump

To contact the KMT Waterjet Systems Spare Parts Department: USA Europe Parts Department Spare Parts Manager KMT Waterjet Systems KMT Waterjet Systems 635 West 12th Street / POB 231 Auf der Laukert 11 Baxter Springs, KS 66713-0231 D–61231 Bad Nauheim USA Germany Phone: (620) 856–2151 Phone: +49–(0)6032–997–115 Fax: (620) 856–5050 Fax: +49–(0)6032–997–271 E-mail: [email protected] E-mail: [email protected]

01/2004 12 - 1

SECTION 12 PARTS LIST

12.1 General This section contains parts lists for service procedures and part identification, along with electrical and plumbing schematics of the SL-IV Waterjet Pump. The reader can use these parts lists to identify the part on a drawing, then find the part number and part description corresponding to the drawing balloon number. Replacement parts can be ordered with this part number information.

12.2 Part Nomenclature The following abbreviations and numerical sizes are used for part descriptions in these parts lists:

Table 12-1 Part Description Abbreviations and Nominal Size Guide Item Description Assy Assembly Nominal sizes in fractions of an inch, eg, 1/2 NPT ~ 0.50-inch 1/4, 9/16, national pipe thread, or 9/16 HP tube ~ 0.56-inch OD HP 3/4 tubing or tube fitting Hyd Hydraulic ID or OD Inside diameter or outside diameter Pounds per inch or thousands of pounds per square psi or ksi inch HP and hp HP: High Pressure, hp: horsepower SAE O-ring O-ring threaded port style, SAE standard mm sq. Square millimeters JIC 37-degree flared, threaded hydraulic fitting, JIC standard, typically used on hydraulic hose end connections. Dia Diameter Deg Degree -4,-8,-12 Hydraulic fitting nominal size, in 1/16 th’s of an inch, eg, 1/2 OD tube ~ -8 NO or NC Normally open or normally closed

01/2004 12 - 2

ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

A. HOCHDRUCKWASSERSYSTEM / A. HIGH PRESSURE WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5144217 1. DRUCKÜBERSETZER FLANSCH-VERSION <---> 1. INTENSIFIER FLANGE DESIGN

April 2003 1. DRUCKÜBERSETZER FLANSCH-VERSION <---> 1. INTENSIFIER FLANGE DESIGN 12 - 3 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5144217 1. DRUCKÜBERSETZER FLANSCH-VERSION <---> 1. INTENSIFIER FLANGE DESIGN

Pos. CPN Qty. Bezeichnung Description 01 051446472 KÖRPER HD-ZYLINDER SLIV FD BODY, HD-CYLINDER, SLIV FD 02 051191512 KOLBENSTANGE 7/8" KERAMIK PLUNGER, 7/8", CERAMIC 03 051446882 DICHTKOPF KOMPLETT AUSGANG SLIV FD SEAL HEAD, ASSY, PORT, SLIV FD 04 051479132 KOPF HD-ZYL SLIV FD HEAD,HD-ZYL,SLIV FD 05 051497032 DICHTSATZ HYPERLIFE SLIV FD SEAL ASSY-HP FD, .875 06 051446962 DISTANZRING, DICHTKOPF SLIV FD SPCR-SEAL HD, SL4K 07 051442252 FLANSCHRING SL-IV FLANGE RING SL-IV 08 051300912 DICHTUNG HYDRAULIK "CARTRIDGE" NEU SEAL ASSY, HYDRAULIC "CARTRIDGE" NEW 09 050077862 FLANSCH DICHTUNG HYDRAULIK "CARTRIDGE" FLANGE, SEAL HYDRAULIC, "CARTRIDGE" 10 0514475312 STEHBOLZEN 7/8-9 x 6.00 STUD, 7/8-9 x 6.00 11 051447122 BÜCHSE HD-ZYL, 1.12X8.63, ERTALYTE LINER-HP CYL, 1.12X8.63, ERTALYTE 12 100749044 O-RING ND-WASSER ANSCHLUSSRING SLIII/IV O-RING, RING, LP WATER INLET, SLIII/IV 13 051442092 FLANSCH STIRN SL-IV FLANGE, END, SL-IV 14 050347982 RING FLANSCH HYD. DICHTUNG "CARTRIDGE" RING, FLANGE, HYD. SEAL, "CARTRIDGE" 15 050347641 ZYLINDER HYDRAULIK SLIV CYLINDER, HYDRAULIC, SLIV 16 100750002 O-RING 3-3/4"x4"x1/8" O-RING, 3-3/4"x4"x1/8" 17 050348552 STÜTZRING 3-3/4"x4" RING, BACK-UP, 3-3/4"x42 18 0514110616 SCHRAUBE M14 x 60 SCREW, CAP, M14 x 60 19 051275842 SCHALTER NÄHERUNG 20-250 VAC/VAC SWITCH, PROXIMITY, 20-250 VAC/VAC 20 101835724 SCHRAUBE INNENSECHSKANT M6-1x30 MM SCREW SOCKET HEAD, M6-1x30 MM 21 051322531 KOLBEN HYDRAULIK KOMPLETT, SL-IV+ PISTON ASSY HYDRAULIK, SL-IV+ 22 1006990412 MUTTER-SECHSKANT ZUGANKER SLI/SLII NUT, HEAVY HEX, 7/8"- 9 SLI/SLII 23 050498122 ZYLINDER HALTERUNG DRUCKÜBERSETZER SLIV STEM, MOUNTING TOPWORKS, SLIV 25 050796528 SCHRAUBE INNENSECHSKANT M10-1.5 x 85 mm SCREW, SOCKET HEAD, M10-1.5 x 85 mm 26 050614868 FEDERRING M10 WASHER, LOCK, M10 27 100744092 O-RING 1"x1-1/4"x1/8" O-RING, 1"x1-1/4"x1/8" 28 051441832 ABSTANDHALTER NÄHRUNGSSCHALTER (AB) SLIV SPACER, PROXIMITY SWITCH (AB), SLIV

April 2003 1. DRUCKÜBERSETZER FLANSCH-VERSION <---> 1. INTENSIFIER FLANGE DESIGN 12 - 4 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5144217 1. DRUCKÜBERSETZER FLANSCH-VERSION <---> 1. INTENSIFIER FLANGE DESIGN

Pos. CPN Qty. Bezeichnung Description 29 050818722 DICHTUNG HALTERUNG HYD. ZYLINDER SL-IV GASKET, STEM, HYD. CYLINDER, SL-IV

April 2003 1. DRUCKÜBERSETZER FLANSCH-VERSION <---> 1. INTENSIFIER FLANGE DESIGN 12 - 5 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

A. HOCHDRUCKWASSERSYSTEM / A. HIGH PRESSURE WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5144688 2. DICHTKOPF SITZVENTIL <---> 2. SEALING HEAD POPPET SEAT

April 2003 2. DICHTKOPF SITZVENTIL <---> 2. SEALING HEAD POPPET SEAT 12 - 6 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5144688 2. DICHTKOPF SITZVENTIL <---> 2. SEALING HEAD POPPET SEAT

Pos. CPN Qty. Bezeichnung Description 01 051443571 KÖRPER DICHTKOPF AUSGANG SLIV BODY, SEAL HEAD, PORT, SLIV 02 051446621 SCHEIBE DICHTUNG ND-WASSEREIN SLIV FD VALVE, POPPET, LP WATER INLET SLIV FD 03 051167771 MUTTER DICHTKOPF SITZVENTIL SL-IV NUT, GLAND, SEAL HEAD, POPPET SL-IV 04 051127681 SITZ DICHTKOPF 17MM SL-IV 100HP SEAT, SEAL HEAD, 17MM, SL-IV 100HP 05 051165611 SITZ DICHTKOPF SITZVENTIL SL-IV SEAT, SEAL HEAD, POPPET SL-IV 06 051446701 HALTERUNG FEDER WASSEREING. SLIV FD RETAINER, POPPET, LP-WATER SLIV FD 07 051478631 FEDER RÜCKSCHLAGVENTIL SLIV FD SPRING, CHECK VALVE, SLIV FD 08 498845621 FEDER ND-WASSEREINGANG SLIII/IV SPRING, LP-WATER INLET, SLIII/IV 09 051167511 HALTERUNG SITZVENTIL SL-IV RETAINER, POPPET VALVE, SL-IV

April 2003 2. DICHTKOPF SITZVENTIL <---> 2. SEALING HEAD POPPET SEAT 12 - 7 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

A. HOCHDRUCKWASSERSYSTEM / A. HIGH PRESSURE WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5132253 3. HYDRAULIKKOLBEN <---> 3. PISTON ASSY HYDRAULIC

April 2003 3. HYDRAULIKKOLBEN <---> 3. PISTON ASSY HYDRAULIC 12 - 8 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5132253 3. HYDRAULIKKOLBEN <---> 3. PISTON ASSY HYDRAULIC

Pos. CPN Qty. Bezeichnung Description 01 051322611 KOLBEN HYDRAULIK SL-IV 08/01 PISTON, RAM, HYDRAULIC, SL-IV 08/01 02 0507438012 RÜCKHALTESTIFT KOLBENSTANGE SLIV PIN, RETAINING, PLUNGER SLIV 03 050498872 STOPFEN VERSCHLUSS HYDRAULIKKOLBEN SLIV PLUG, HEX, HYDRAULIC PISTON SLIV 04 101487572 VENTIL RÜCKSCHLAG HYD. KOLBEN SLIV VALVE, CHECK, HYD. PISTON SLIV 06 050883642 RING STAHLBAND HALTERING PINS RING SNAP, FLAT STEEL BAND,RETAINER PINS 07 050499942 STÜTZRING O-RING HYD. KOLBEN SLIV RING, BACK-UP, O-RING, HYD. PISTON SLIV 08 050877132 O-RING 1-1/4"x1-1/2"x1/8" O-RING, 1-1/4"x1-1/2"x1/8" 09 051179651 DICHTSATZ HYDRAULIKKOLBEN SL-IV NEU SEAL ASSY, HYDRAULIC PISTON, SL-IV 10 051179402 GLEITRING HYDRAULIKKOLBEN SL-IV NEU RING, GLIDE, HYDRAULIC PISTON, SL-IV

April 2003 3. HYDRAULIKKOLBEN <---> 3. PISTON ASSY HYDRAULIC 12 - 9 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

A. HOCHDRUCKWASSERSYSTEM / A. HIGH PRESSURE WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5069703 4. VENTIL DRUCKENTLASTUNG HD-WASSER <---> 4. VALVE DUMP HP WATER

April 2003 4. VENTIL DRUCKENTLASTUNG HD-WASSER <---> 4. VALVE DUMP HP WATER 12 - 10 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5069703 4. VENTIL DRUCKENTLASTUNG HD-WASSER <---> 4. VALVE DUMP HP WATER

Pos. CPN Qty. Bezeichnung Description 01 100784591 MUTTER ÜBERWURF HOCHDRUCK 1/4" NUT, GLAND, HP, 1/4" 02 100784261 ROHRMUTTER 1/4" HOCHDRUCK COLLAR, HP, 1/4" 03 100792911 DRUCKSTÜCK KONUSTEIL 9/16" CONE, 9/16", SAFETY HEAD 04 498643091 ADAPTER 9/16"x1/4" ADAPTER, 9/16"x1/4" 05 101786971 NADELSITZ AUSTAUSCHBAR PNEUM. VENTIL SEAT, REPLACEABLE, PNEUMATIC VALVE 06 101789781 DICHTSATZ PNEUMATIKVENTIL ø 0.25" SEAL ASSY, PNEUMATIC VALVE, ø 0.25" 07 101882331 STÜTZRING PNEUMATIKVENTIL ø 0.25" RING, BACK-UP, PNEUMATIC VALVE ø 0.25" 08 101872501 STÜTZRING ZYLINDER PNEUMATIKVENTIL RING, BACK-UP, ACTUATOR, PNEU. VALVE 09 498658431 NADEL PNEUMATIKVENTIL 3/8" STEM, PNEUMATIC VALVE, 3/8" 10 100745652 O-RING 2-1/4"x2-3/8"x1/16" VITON O-RING, 2-1/4"x2-3/8"x1/16" VITON 11 100747141 O-RING 2-7/16"x2-5/8"x3/32" VITON O-RING, 2-7/16"x2-5/8"x3/32" VITON 12 498941731 DECKEL PNEUMATIKVENTIL N/O (OBEN) COVER, TOP, PNEUMATIC VALVE, N/O 13 054501761 VERSCHRAUBUNG 1/8"x1/8" MESSING ADAPTER, MALE, 1/8"x1/8", BRASS 14 498908251 SCHALLDÄMPFER MAGNETVENTIL 5.4-8.5 W SILENCER, SOLENOID VALVE, 5.4-8.5 W 15 100770301 KUPPLUNG 90° MÄNNLICH 0.25"x0.13" COUPLING, 90°, MALE, 0.25"x0.13" 16 498880351 MAGNETVENTIL 2/3-WEGE 24VDC 5.4 W VALVE, SOLENOID, 2/3-WAY, 24VDC, 5.4 W 17 498941991 ZYLINDER PNEUMATIKVENTIL N/O CYLINDER, PNEUMATIC VALVE, N/O 18 498941811 KOLBEN PNEUMATIKVENTIL N/O PISTON, PNEUMATIC VALVE, N/O 19 101891811 KÖRPER PNEUMATIKVENTIL ø 0.25" BODY, PNEUMATIC VALVE, ø 0.25" 20 498645641 MUTTER STABILISIERUNG SPANNZANGE 3/8" COLLET, GLAND, ANTIVIBRATION, 3/8" 21 498646221 ROHRMUTTER 3/8" HOCHDRUCK COLLAR, HP, 3/8"

April 2003 4. VENTIL DRUCKENTLASTUNG HD-WASSER <---> 4. VALVE DUMP HP WATER 12 - 11 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

A. HOCHDRUCKWASSERSYSTEM / A. HIGH PRESSURE WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5144738 5. HD-WASSERKREISLAUF STANDARD <---> 5. HIGH PRESSURE WATER ASSY SINGLE

April 2003 5. HD-WASSERKREISLAUF STANDARD <---> 5. HIGH PRESSURE WATER ASSY SINGLE 12 - 12 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5144738 5. HD-WASSERKREISLAUF STANDARD <---> 5. HIGH PRESSURE WATER ASSY SINGLE

Pos. CPN Qty. Bezeichnung Description 01 051488611 HD-ROHR 3/8"GEBOGEN SLIV FD TOPW. TUBE HP 3/8"BENT SLIV FD TOPW. 02 051488531 HD-ROHR 3/8" GEBOGEN SLIV FD P.2 TUBE HP 3/8" BENT SLIV FD 03 100785902 KUPPLUNG HOCHDRUCK T-STÜCK 3/8" COUPLINH, HP, TEE, 3/8" 04 498646632 STOPFEN 9/16" HD-ROHR PLUG, 9/16", HP-TUBE 05 051488461 HD-ROHR 3/8" GEBOGEN 4150 TUBE HP 3/8" BENT 4150 06 100781292 MUTTER ÜBERWURF HD 3/8" NUT, GLAND, HP, 3/8" 07 100787152 ROHRMUTTER 3/8" HD COLLAR, HP, 3/8" 08 051442171 DRUCKÜBERSETZER KOMPLETT SL-IVPLUS TOPWORKS, INTENSIFIER, SL-IVPLUS 09 050406961 DRUCKSPEICHER TÜV 1 LITER SLIV ACCUMULATOR, TUV, 1 LITER, SLIV 11 498305992 KUPPLUNG HD T-STÜCK 9/16 x 3/8" COUPLING HP TEE 9/16 x 3/8" 12 100838978 ENDRING, ROHRSCHUTZ, 1/4" FERRULE, 1/4" 13 954136964 FEDERRING 1/2"x0.125" WASHER, LOCK, 1/2"x0.125" 14 051448374 ABSTANDSHALTER, DRUCKSPEICHER SPACER, ACCUMULATOR 15 953837904 SCHRAUBE INNENSECHSKANT 1/2"x1" SCREW, SOCKET HEAD, 1/2"x1" 16 050907172 MUTTER GEHÄUSE DRUCKSPEICHER SLIV NUT, HOUSING, ACCUMULATOR, SLIV 17 101861533,8 SCHLAUCH SCHUTZ HD-ROHR 1/4"&3/8" CONDUIT, PROTECTION, HP TUBE 1/4"&3/8" 18 051488201 HD-ROHR 3/8" GEBOGEN SLIV FD P.18 TUBE HP 3/8" BENT SLIV FD 19 101054431 HD-NIPPELROHR 3/8" L=101,6MM HP-NIPPLE TUBE, 3/8" L=4" 20 100787801 KUPPLUNG HD 90° 3/8" COUPLING, HP, 90°, 3/8" 22 050697031 ENTLASTUNGSVENTIL PNEUMATISCH SLIV VALVE ASSY, DUMP, PNEUMATIC, SLIV 23 050805281 HD-NIPPELROHR 1/4"x25.5" HP-NIPPLE TUBE, 1/4"x25.5" 24 100947042 HD-NIPPELROHR 3/8" L=76mm HP-NIPPLE TUBE 3/8" L=3" 25 498305811 HD-ROHR 3/8" GEBOGEN SLIV FD P.25 TUBE HP 3/8" BENT SLIV FD 26 100902801 VERSCHRAUBUNG SCHOTT 9/16" COUPLING, BULKHEAD, 9/16"

April 2003 5. HD-WASSERKREISLAUF STANDARD <---> 5. HIGH PRESSURE WATER ASSY SINGLE 12 - 13 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

B. HYDRAULIKSYSTEM / B. HYDRAULIC SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5071741 1. HYDRAULIKANTRIEBSEINHEIT <---> 1. HYDRAULIC POWER PACKAGE

April 2003 1. HYDRAULIKANTRIEBSEINHEIT <---> 1. HYDRAULIC POWER PACKAGE 12 - 14 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5071741 1. HYDRAULIKANTRIEBSEINHEIT <---> 1. HYDRAULIC POWER PACKAGE

Pos. CPN Qty. Bezeichnung Description 01 050717581 BAUGRUPPE MOTOR/PUMPE SLIV-50HP MOTOR/PUMP ASSY, SLIV-50HP 02 050491681 ADAPTER BOOSTERPUMPE SLIV ADAPTER, BOOSTER PUMP, SLIV 03 955728973 SCHRAUBE SECHSKANT 1/4"x5/8" SCREW, HEX HEAD, 1/4"x5/8" 04 958383143 SCHEIBE 1/4"x0.063" WASHER, LOCK, 1/4"x0.063" 05 498870941 PUMPE DRUCKERHÖHUNG V2A SLIV-PLUS PUMP, BOOSTER, WATER, SS, SLIV-PLUS 12 100923021 KUPPLUNG DRUCKERHÖHERPUMPE SLIII/IV COUPLING, SHAFT, BOOSTER PUMP, SLIII/IV 13 101169522 STOPFEN, ADAPTER BOOSTER SLIV PLUG, ADAPTER BOOSTER, SLIV 14 957503942 SCHEIBE 3/8"x0.094" WASHER, LOCK, 3/8"x0.094" 15 954163192 SCHRAUBE SECHSKANT 3/8"x1" SCREW, HEX HEAD, 3/8"x1" 16 100915101 AUFKLEBER PFEIL DREHRICHTUNG DECAL, ARROW, DIRECTION ROTATION 18 050925231 VENTIL UMSTEUERUNG 24VDC SLIV 30/50HP VALVE, CONTROL, 24VDC SLIV 30/50HP 19 950550266 SCHRAUBE I-SECHSKANT 1/2"x1-3/4" SCREW, SOCKET HEAD, 1/2"x1-3/4" 20 956887506 SCHEIBE 1/2"x0.172" WASHER, LOCK, 1/4"x0.172" 21 100697142 SCHEIBE 3/8"x0.078 WASHER, FLAT, 3/8"x0.078"

April 2003 1. HYDRAULIKANTRIEBSEINHEIT <---> 1. HYDRAULIC POWER PACKAGE 12 - 15 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

B. HYDRAULIKSYSTEM / B. HYDRAULIC SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5071758 2. BAUGRUPPE MOTOR/PUMPE <---> 2. MOTOR/PUMP ASSEMBLY

April 2003 2. BAUGRUPPE MOTOR/PUMPE <---> 2. MOTOR/PUMP ASSEMBLY 12 - 16 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5071758 2. BAUGRUPPE MOTOR/PUMPE <---> 2. MOTOR/PUMP ASSEMBLY

Pos. CPN Qty. Bezeichnung Description 03 051016132 VIBRATIONSDÄMPFER MOTOR SLIV 50HP ISOLATOR, VIBRATION, MOTOR SLIV 50HP 04 050455131 MOTORHAUPTANSLIV50HP37kW)U N G Ü L T I G MOTOR,ELECTRICAL,SLIV50HP(37kW) 05105234 06 050475191 PASSFEDER SLIV 50HP MOTOR/HYD. PUMPE KEY, SLIV 50HP, MOTOR/HYD. PUMP 07 050455051 PUMPE HYDRAULIK VERSTELLBAR SLIV 50HP PUMP, HYDRAULIC, VARIABLE, SLIV 50HP 08 050375932 SCHRAUBE INNENSECHSKANT M10x25mm SCREW, SOCKET HEAD, M10x25mm 09 100697141 SCHEIBE 3/8"x0.078 WASHER, FLAT, 3/8"x0.078" 10 050717661 BLOCK HYDRAULIK KOMPLETT SLIV MANIFOLD ASSY, HYDRAULIC, SLIV 11 050474511 ADAPTER 90° JIC/O-RING 3/4" ADAPTER, 90°, O-RING/JIC, 3/4" 12 050453641 PUMPE HYDRAULIK ZAHNRAD SLIV PUMP, HYDRAULIC, GEAR, SLIV 16 050917564 SCHRAUBE INNENSECHSKANT 7/16"x6" SCREW, SOCKET HEAD, 7/16"x6"

April 2003 2. BAUGRUPPE MOTOR/PUMPE <---> 2. MOTOR/PUMP ASSEMBLY 12 - 17 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

B. HYDRAULIKSYSTEM / B. HYDRAULIC SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5071766 3. HYDRAULIKBLOCK <---> 3. MANIFOLD ASSY HYDRAULIC

April 2003 3. HYDRAULIKBLOCK <---> 3. MANIFOLD ASSY HYDRAULIC 12 - 18 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5071766 3. HYDRAULIKBLOCK <---> 3. MANIFOLD ASSY HYDRAULIC

Pos. CPN Qty. Bezeichnung Description 01 050441441 KÖRPER HYDRAULIKBLOCK SLIV BODY, HYDRAULIC MANIFOLD, SLIV 02 050710554 STOPFEN INNENSECHSKANT O-RING 3/4" PLUG, SOCKET HEAD, O-RING 3/4" 03 050717171 VENTIL ÜBERSTRÖMUNG 3200 PSI (220 BAR) VALVE, RELIEF, 3200 PSI (220 BAR) 04 050550172 STOPFEN INNENSECHSKANT O-RING 1/4" PLUG, SOCKET HEAD, O-RING 1/4" 05 101855851 MAGNETVENTIL 2/2-WEGE 24VDC N/O VALVE, SOLENOID, 2/2 WAY, 24VDC N/O 06 050454971 MANOMETER HYDRAULIKDRUCK SLIV GAUGE, PRESSURE, HYDRAULIC SLIV 07 101870521 VENTIL ÜBERSTRÖMUNG 1/4" 100-3000 PSI VALVE, RELIEF, 1/4" 100-3000 PSI 08 101870601 VENTIL ÜBERSTRÖMUNG 1/4" 25-800 PSI VALVE, RELIEF, 1/4" 25-800 PSI 09 100749531 O-RING 1-1/2"x1-3/4"x1/8" O-RING, 1-1/2"x1-3/4"x1/8" 10 498897441 HALTERUNG RÜCKSCHLAGVENTIL SLIII/IV RETAINER, HYD. CHECK VALVE, SLIII/IV 11 498897361 VENTIL RÜCKSCHLAG CARTRIDGE SLIII/IV VALVE, CHECK, CARTRIDGE, SLIII/IV 12 101895951 SATZ O-RINGE 4-WEGE UMSTEUERVENTIL KIT, O-RING, 4-WAY VALVE

April 2003 3. HYDRAULIKBLOCK <---> 3. MANIFOLD ASSY HYDRAULIC 12 - 19 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

B. HYDRAULIKSYSTEM / B. HYDRAULIC SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5052519 4. HYDRAULIKSCHLÄUCHE <---> 4. HYDRAULIC HOSE CONNECTIONS

April 2003 4. HYDRAULIKSCHLÄUCHE <---> 4. HYDRAULIC HOSE CONNECTIONS 12 - 20 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5052519 4. HYDRAULIKSCHLÄUCHE <---> 4. HYDRAULIC HOSE CONNECTIONS

Pos. CPN Qty. Bezeichnung Description 01 050607441 SCHLAUCH ND-HYDRAULIK 3/4" L=445 mm HOSE ASSY, LP HYDRAULIC, 3/4" L=445 mm 02 050497051 SCHLAUCH ND-HYDRAULIK 3/4" L=559 mm HOSE ASSY, LP HYDRAULIC, 3/4" L=559 mm 03 050497391 SCHLAUCH ND-HYDRAULIK 3/4" L=356 mm HOSE ASSY, LP HYDRAULIC, 3/4" L=356 mm 04 100835172 SCHLAUCHSCHELLE 1.81 - 2.75" , HOSE, WORM GEAR, 1.81 - 2.75" 05 101790180,16 SCHLAUCH HYDRAULIKPUMPE SLII/IV HOSE ASSY, HYDRAULIC PUMP, SLII/IV 06 050487801 FLANSCH 2-TEILIG 2" FLANGE, SPLIT-KIT, 2" 07 050488061 KUPPLUNG FLANSCH 2-TEILIG/SCHLAUCH 2" COUPLING, SPLIT FLANGE/HOSE, 2" 08 050512141 SCHLAUCH MD-HYDRAULIK 1/4" L=1524 mm HOSE ASSY, MP HYDRAULIC, 1/4" L=1524 mm 09 050607511 SCHLAUCH MD-HYDRAULIK 1/4" L=813 mm HOSE ASSY, MP HYDRAULIC, 1/4" L=813 mm 10 050497131 SCHLAUCH ND-HYDRAULIK 3/4" WEIBLICH HOSE ASSY, LP HYDRAULIC, 3/4" FEMALE 11 050711052 SCHLAUCH HD-HYDRAULIK 3/4" L=1016 mm HOSE ASSY, HP HYDRAULIC, 3/4" L=1016 mm 12 050711211 SCHLAUCH MD-HYDRAULIK 1/4" L= mm HOSE ASSY, MP HYDRAULIC, 1/4" L= mm 13 050524932 KUPPLUNG 45° O-RING/JIC 12-10 COUPLING, 45°, O-RING/JIC, 12-10 14 957026191 ADAPTER GERADE O-RING/JIC 3/4" ADAPTER, STRAIGHT, O-RING/JIC, 3/4" 15 101426442 ADAPTER 90° HYDRAULIKBLOCK SLIII/IV ADAPTER, 90°, HYD. MANIFOLD, SLIII/IV 16 101447491 ADAPTER 45° O-RING/JIC 1/4"x1/4" ADAPTER, 45°, O-RING/JIC, 1/4"x1/4" 17 050711131 ADAPTER O-RING/JIC 3/4" ADAPTER, O-RING/JIC 3/4" 18 050503311 KUPPLUNG 90° JIC/O-RING 12-10 COUPLING, 90°, JIC/O-RING, 12-10 19 101425941 ADAPTER GERADE JIC/O-RING 12-16 ADAPTER, STRAIGHT, JIC/O-RING, 12-16 20 050607771 ADAPTER 45° JIC M/W 12-12 ADAPTER, 45°, JIC, M/F 12-12

April 2003 4. HYDRAULIKSCHLÄUCHE <---> 4. HYDRAULIC HOSE CONNECTIONS 12 - 21 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

C. NIEDERDRUCKWASSERSYSTEM / C. LOW PRESSURE WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5140009 1. ND-WASSERFILTER PLASTIK <---> 1. FILTER ASSY LP WATER PLASTIC

April 2003 1. ND-WASSERFILTER PLASTIK <---> 1. FILTER ASSY LP WATER PLASTIC 12 - 22 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5140009 1. ND-WASSERFILTER PLASTIK <---> 1. FILTER ASSY LP WATER PLASTIC

Pos. CPN Qty. Bezeichnung Description 01 498307142 ADAPTER 90° -4 NPT X -4 SCHLAUCH ADAPTER 90° -4 NPT X -4 HOSE 02 051296891 STOPFEN O-RING 1/2" PLUG, O-RING, 1/2" 03 050709821 VENTIL ÜBERSTRÖMUNG 1/2" 50 - 150 PSI VALVE, RELIEF, 1/2" 50 - 150 PSI 04 050740672 NIPPELROHR WASSER 1/2"x3" NIPPLE, PIPE, 1/2"x3" 05 100781112 ADAPTER ROHR M/W 3/4"x1/2" ADAPTER, PIPE, M/F 3/4"x1/2" 06 051356111 ANSCHLUSSBLOCK, ND-EINLASS, SLIV MANIFOLD, LP-INLET, SLIV 07 051420702 ANSCHLUSSBLOCK, ND-MANOMETER SLIV MANIFOLD, LP-GAUGE, SLIV 08 051356604 WINKEL, ND-WINKEL, VON BOOSTER AUSLASS ELBOW, LP-WATER, FROM BOOSTER OUTLET 09 498307301 ADAPTER -8 NPT X -8 SCHLAUCH ADAPTER, -8 NPT X -8 HOSE 10 050386901 KÖRPER ND-WASSERFILTER SLIV BODY, LP WATER FILTER, SLIV 11 051356521 RÜCKSCHLAGVENTIL, ND-WASSER, SLIV VALVE, CHECK, LP-WATER, SLIV 12 101004851 ADAPTER SCHLAUCHANSCHLUSS M/M1,2" x 1,2 ADAPTER, PIPE/HOSE, 1/2" x 1/2" 13 051407511 DRUCKSCHALTER; 30PSI PRESSURE SWITCH; 30PSI 14 101067222 FILTER-ELEMENT WASSER 10 MICRON ABS. FILTER ELEMENT, WATER, 10 MICRON ABS. 15 101890251 ADAPTER SCHLAUCH/JIC 1/2"x1/2" ADAPTER, HOSE/JIC, 1/2"x1/2" 16 101140232 BÜGELSCHRAUBE Ý1/2" - 1/4"x1"x1-3/4" U-BOLT, Ý1/2" - 1/4"x1"x1-3/4" 19 954163354 MUTTER SECHSKANT 1/4"-20 NUT, HEX, 1/4"-20 20 958383144 SCHEIBE 1/4"x0.063" WASHER, LOCK, 1/4"x0.063" 21 953913224 SCHEIBE 1/4"x0.063" WASHER, FLAT, 1/4"x0.063" 23 051420621 DRUCKSCHALTER; 60 PS I PRESSURE SWITCH; 60 PS I

April 2003 1. ND-WASSERFILTER PLASTIK <---> 1. FILTER ASSY LP WATER PLASTIC 12 - 23 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

D. KÜHLWASSERSYSTEM / D. COOLING WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5041660 1. ÖLTANK <---> 1. RESERVOIR ASSY

April 2003 1. ÖLTANK <---> 1. RESERVOIR ASSY 12 - 24 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5041660 1. ÖLTANK <---> 1. RESERVOIR ASSY

Pos. CPN Qty. Bezeichnung Description 01 050416861 ÖLTANK SLIV GESCHWEISST RESERVOIR, SLIV, WELDMENT 02 050498611 DICHTUNG ÖLTANK SLIV GASKET, OIL RESERVOIR, SLIV 03 050500261 SCHALTER TEMPERATUR/ÖLNIVEAU 1" SLIV SWITCH, TEMPERATURE/LEVEL, 1" SLIV 04 050927391 VERSCHLUSSKAPPE ÖLTANK SLIV CAP, FILLER, OIL RESERVOIR, SLIV 05 101688621 MANOMETER TEMPERATUR/ÖLNIVEAU 2x SKALA GAUGE, TEMP./OIL LEVEL, DUAL SCALE 06 050496971 FILTERKOPF ÖL MIT MANOMETER SLIV FILTER, HEAD, OIL, WITH GAUGE, SLIV 07 050496891 FILTERELEMENT ÖL 6 MIKRON ABSOL. SLIV FILTER ELEMENT, OIL, 6 MICRON,ABS.SLIV 08 050496553 KUPPLUNG 90° ROHR/JIC 16x12 COUPLING, 90°, PIPE/JIC, 16x12 09 050699761 STOPFEN VERSCHLUSS ÖLBEFÜLLUNG SLIV PLUG, HEX, OIL FILL PORT, SLIV 10 050710631 T-STÜCK MÄNNLICH O-RING/JIC 3/4" TEE, MALE, O-RING/JIC, 3/4" 11 050497131 SCHLAUCH ND-HYDRAULIK 3/4" WEIBLICH HOSE ASSY, LP HYDRAULIC, 3/4" FEMALE 12 051459581 WÄRMETAUSCHER SL-IV-PLUS HEAT EXCHANGER SL-IV-PLUS 13 958307661 FEDERRING 0.31"x0.078" WASHER, LOCK, 0.31"x0.078" 14 101032321 PLATTE, NEOPREN, 0,13 x 1 PLATE, NEOPREN, 0,13 x 1 15 100918581 GLÜHBIRNE 3/4" BULB, 3/4" 16 951198974 SCHRAUBE, INNENSECHSKANT, 5/16"-18 x 1/2 SCREW, HEX, 5/16"-18 x 1/2 17 051459741 HALTERUNG, WÄREMTAUSCHER BRACKET, HEAT EXCHANGER 18 957168904 FEDERRING 1/2"x0.031" WASHER, LOCK, 1/2"x0.031" 19 100697634 SCHEIBE 1/2"x0.109" WASHER, FLAT, 1/2"x0.109" 20 050575591 ADAPTER GERADE O-RING/JIC 3/4" ADAPTER, STRAIGHT, O-RING/JIC, 3/4" 21 498685241 REDUZIERUNG 1-1/4" x 1" (A-I) ADAPTER, REDUCING, 1-1/4" x 1" (M-F) 22 050062911 DIFFUSOR RÜCKLEITUNG 1-1/4" DIFFUSOR, RETURN LINE, 1-1/4" 23 100999011 KUPPLUNG 90° ROHR/JIC 4-4 COUPLING, 90°, PIPE/JIC, 4-4 24 100809011 VENTIL KUGELHAHN 1/2" VALVE, BALL, 1/2" 26 950336191 STOPFEN VIERKANT 1/2" PLUG, SQUARE HEAD, 1/2" 27 958979484 SCHRAUBE RUNDKOPF 10-24x1/2" SCREW, BUTTON HEAD, 10-24x1/2" 28 953677284 FEDERRING 10x0.047" WASHER, LOCK, 10x0.047"

April 2003 1. ÖLTANK <---> 1. RESERVOIR ASSY 12 - 25 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5041660 1. ÖLTANK <---> 1. RESERVOIR ASSY

Pos. CPN Qty. Bezeichnung Description 29 100998771 ADAPTER GERADE ROHR/JIC 1/4" ADAPTER, STRAIGHT, PIPE/JIC, 1/4" 32 050503312 KUPPLUNG 90° JIC/O-RING 12-10 COUPLING, 90°, JIC/O-RING, 12-10 33 050793711 ADAPTER GERADE JIC/BSPP 12-12 ADAPTER, STRAIGHT, JIC/BSPP 12-12 35 050799671 DICHTUNG SCHALTER ÖLTEMP./NIVEAU SLIV GASKET, SWITCH OIL TEMP./LEVEL, SLIV 36 957385144 SCHRAUBE SECHSKANT 1/2"x1" SLIII SCREW, HEX HEAD, 1/2"x1" SLIII

April 2003 1. ÖLTANK <---> 1. RESERVOIR ASSY 12 - 26 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

D. KÜHLWASSERSYSTEM / D. COOLING WATER SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5100318 2. VERSORGUNGSANSCHLÜSSE <---> 2. BULKHEAD PIPE ASSEMBLY

April 2003 2. VERSORGUNGSANSCHLÜSSE <---> 2. BULKHEAD PIPE ASSEMBLY 12 - 27 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5100318 2. VERSORGUNGSANSCHLÜSSE <---> 2. BULKHEAD PIPE ASSEMBLY

Pos. CPN Qty. Bezeichnung Description 01 101474602 KUPPLUNG 90° ROHR/JIC 8-8 MESSING COUPLING, 90°, PIPE/JIC, 8-8 BRASS 02 100918661 VENTIL WASSERTEMPERATUR SLIII VALVE, WATER, TEMPERATURE, SLIII 03 050602071 ROHR EDELSTAHL 1/2" x 5" PIPE, STAINLESS STEEL, 1/2" x 5" 04 101924252 ADAPTER 1/2" NPT X 1/2" SCHLAUCH ADAPTER, 1/2" NPT X 1/2" HOSE 05 498902391 MAGNETVENTIL 24VDC-1/2" ND-WASSER SLII VALVE, SOLENOID, 24VDC-1/2", LP-WATER 06 498869224 SCHOTTVERSCHRAUBUNG 8-24 ADAPTER, BULKHEAD, 8-24 07 101273487,1 SCHLAUCH WASSERZUFUHR SLII HOSE, WATER INLET, SLII 08 050710221 HD-NIPPELROHR 3/8" GEBOGEN HP-NIPPLE TUBE, 3/8" BENT 09 100700924 MUTTER SCHOTTVERSCHRAUBUNG ND-WASSER NUT, JAM, BULKHEAD CONNECTOR, LP-WATER 10 498967491 T-STÜCK MÄNNLICH 1/2" EDELSTAHL TEE, MALE, 1/2", STAINLESS STEEL 11 050616432 STOPFEN 1-1/2" PLUG, 1-1/2" 12 051054321 BAUGRUPPE ND-WASSERFILTER SL-IV V2A FILTER ASSY, LP WATER, SL-IV SS 13 050871431 ADAPTER ROHR/SCHLAUCH 1/4"x1/2" MÄNNLICH ADAPTER, TUBE/PIPE, 1/4"x1/2" MALE 14 050613122 DECKEL VERSCHLUSS 2-1/2" SLIV CAP, SEAL HOLE, 2-1/2", SLIV 15 050805281 HD-NIPPELROHR 1/4"x25.5" GEBOGEN HP-NIPPLE TUBE, 1/4"x25.5", BENT 16 100770551 SCHOTTVERSCHRAUBUNG 4-15 MESSING ADAPTER, BULKHEAD, 4-15, BRASS 17 050697031 ENTLASTUNGSVENTIL PNEUMATISCH SLIV VALVE ASSY, DUMP, PNEUMATIC, SLIV 18 498645071 KUPPLUNG HOCHDRUCK T-STÜCK 3/8" COUPLING, HP, TEE, 3/8" 19 100697634 SCHEIBE 1/2"x0.109" WASHER, FLAT, 1/2"x0.109" 20 100947041 HD-NIPPELROHR 3/8" L=76mm HP-NIPPLE TUBE 3/8" L=3" 21 100794571 ADAPTER MÄNNLICH/WEIBLICH 9/16"x3/8" ADAPTER, MALE/FEMALE, 9/16"x3/8" 22 498643411 VERSCHRAUBUNG SCHOTT 9/16" COUPLING, BULKHEAD, 9/16" 23 101767661 KUPPLUNG 90° KUNSTSTOFF 1/4"x1/4" COUPLING, 90°, POLY, 1/4"x1/4" 24 101890254 ADAPTER SCHLAUCH/JIC 1/2"x1/2" ADAPTER, HOSE/JIC, 1/2"x1/2" 25 051113982 SCHNELLKUPPLUNG ND-WASSER 1/4" SL-IV 100 QUICK DISCONNECT, LP WATER, SL-IV 100HP 26 957385144 SCHRAUBE SECHSKANT 1/2"x1" SLIII SCREW, HEX HEAD, 1/2"x1" SLIII 27 101706864 FEDERRING 1/2"x0.125" WASHER, LOCK, 1/2"x0.125"

April 2003 2. VERSORGUNGSANSCHLÜSSE <---> 2. BULKHEAD PIPE ASSEMBLY 12 - 28 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5100318 2. VERSORGUNGSANSCHLÜSSE <---> 2. BULKHEAD PIPE ASSEMBLY

Pos. CPN Qty. Bezeichnung Description 28 101861530,6 SCHLAUCH SCHUTZ HD-ROHR 1/4"&3/8" CONDUIT, PROTECTION, HP TUBE 1/4"&3/8" 30 100782930,6 SCHLAUCH KUNSTSTOFF 1/4" TRANSP. HOSE, POLY, 1/4", TRANSPARENT 31 101054431 HD-NIPPELROHR 3/8" L=101,6MM HP-NIPPLE TUBE, 3/8" L=4" 32 101458292 DOPPELNIPPEL TEMP. SENSOR 1/2" NIPPLE, DOUBLE, TEMP. SENSOR, 1/2" 33 100825501 ADAPTER VENTIL/KÜHLER 1/2"(MS) ADAPTER, VALVE/HEAT EXCHANGER, 1/2" 34 051113802 SCHNELLKUPPLUNG ND-WASSER 1/4" SL-IV 100 QUICK DISCONNECT, LP WATER, SL-IV 100HP 36 051114062 ADAPTER SCHNELLKUPPLUNG SL-IV 100 ADAPTER, QUICK DISCONNECT, SL-IV 100HP 37 498869892 ADAPTER ROHR/JIC GERADE 6-8 EDELSTAHL ADAPTER, PIPE/JIC, STRAIGHT 6-8, SS 38 498914682 SCHLAUCHANSCHLUSS KOMPLETT SLII FITTING, HOSE, PUSH-LOK, MALE 39 101738052 SCHLAUCHTÜLLE 1/2"x8JIC MESSING COUPLING, HOSE, 1/2"x8JIC BRASS 40 051139644 SCHLAUCHSCHUTZ GUMMI GROMMET, RUBBER

April 2003 2. VERSORGUNGSANSCHLÜSSE <---> 2. BULKHEAD PIPE ASSEMBLY 12 - 29 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5148556 1. BAUGRUPPE ELEKTRIK <---> 1. ELECTRIC ASSEMBLY

April 2003 1. BAUGRUPPE ELEKTRIK <---> 1. ELECTRIC ASSEMBLY 12 - 30 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5148556 1. BAUGRUPPE ELEKTRIK <---> 1. ELECTRIC ASSEMBLY

Pos. CPN Qty. Bezeichnung Description 01 051485311 KABELBAUM STEUERSCHRANK SLIV+ HARNESS-WIRE CONTROL-PANEL SLIV+ 02 100806611 STECKER GERADE FLEXIBLE 1-1/2" CONNECTOR, STRAIGHT, FLEXIBLE, 1-1/2" 03 051382191 RING, MOTORKLEMMBRETT RING, TERMINAL 04 100867000,46 KABELFÜHRUNG 1-1/2" GRAU CONDUIT, FLEXIBLE, 1-1/2" GRAY 05 101158301 KUPPLUNG 45° KABELFÜHRUNG 1-1/2" COUPLING, 45°, FLEXIBLE CONDUIT, 1-1/2" 06 050813771 HÜLSE KABELFÜHRUNG 1-1/2" BUSHING, CONDUIT, 1-1/2" 07 1015914312 RING MOTORKLEMMBRETT #8-1/4" RING, TERMINAL BLOCK, MOTOR #8-1/4" 08 100697634 SCHEIBE 1/2"x0.109" WASHER, FLAT, 1/2"x0.109" 09 498787546,25 KABEL #6 SCHWARZ WIRE, #6, BLACK 10 101701401,05 KABEL #6/10MM2, GRÜN/GELB WIRE, #6/10MM2, GREEN/YELLOW 11 050440291 ADAPTER FIBERGLASS KLEMMBRETT/MOTOR ADAPTER, FIBERGLASS, MOTOR JUNCTION BOX 12 950770122 SCHRAUBE SECHSKANT 5/16"x1-3/4" SCREW, HEX HEAD, 5/16"x1-3/4" 13 050431611 KLEMMBRETT MOTOR 9-POLIG M6 TERMINAL BLOCK, MOTOR, 9-POST, M6 14 956867212 SCHRAUBE, INNENSECHSKANT, 1/4-20x1-3/4 SCREW, SOCKET HEAD, 1/4-20x1-3/4 15 954236954 MUTTER, SECHSKANT, 1/2-13 NUT, HEX, 1/2-13 16 101743571 RING MOTORKLEMMBRETT #6-1/4" RING, TERMINAL BLOCK, MOTOR #6-1/4" 17 050623442 MUTTER, VERSCHLUSS, 1/4-20 NUT, LOCK, 1/4-20 18 957168904 FEDERRING 1/2"x0.031" WASHER, LOCK, 1/2"x0.031" 19 101259125 KABELBINDER CABLE TIE 20 051485641 STEUERSCHRANK SLIV+KOMPLETT CONTROL-PANEL SLIV+COMPLETE 21 100854052 DICHTUNG KABELKANAL 1.5" GASKET ASSY, FLEX CONDUIT, 1.5" 22 100697552 SCHEIBE FLACH 0.31"x0.078" WASHER, FLAT, 0.31"x0.078"

April 2003 1. BAUGRUPPE ELEKTRIK <---> 1. ELECTRIC ASSEMBLY 12 - 31 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5148564 2. SCHALT-/STEUERSCHRANK <---> 2. STARTER/CONTROL PANEL

April 2003 2. SCHALT-/STEUERSCHRANK <---> 2. STARTER/CONTROL PANEL 12 - 32 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5148564 2. SCHALT-/STEUERSCHRANK <---> 2. STARTER/CONTROL PANEL

Pos. CPN Qty. Bezeichnung Description 01 051380861 SCHALTER SICHERUNG 100A CIRCUIT BREAKER, 100A 02 050819551 SCHRAUBE, INNENSECHSKANT, 8-32x2 SCREW, SOCKET HEAD, 8-32x2 03 051379631 DREHANTRIEB HAUPTSCHALTER SLIV-PLUS DRIVE, ROTARY MECHANISM, SL-IV-PLUS 04 051379891 VERLÄNGERUNG DREHANTRIEB SLIV 50-PLUS EXTENSION, ROTARY HANDLE, SLIV 50-PLUS 05 051379971 DREHANTRIEB HAUPTSCHALTER SLIV 50-PLUS ROTARY HANDLE, CIRC. BREAKER SLIV 50PLUS 06 051379481 ABDECKUNG SCHUTZ COVER, TERMINAL 07 498787543,66 KABEL #6 SCHWARZ WIRE, #6, BLACK 08 1017035520 ADERENDHÜLSE #6/10 MM2 CRIMP, CONNECTOR, #6/10 MM2 09 498334371 SCHÜTZ MOTORANLAUF 81 A CONTACTOR, NONREVERSING, 81A 10 101576678 SCHRAUBE, #10-32 x 3/4 SCREW, #10-32 x 3/4 11 101030340,61 ANSCHLUSSKLEMMLEISTE RAIL, DIN-STEEL 12 051176431 ÜBERLASTRELAIS RELAY, OVERLOAD 13 498334521 HILFSSSCHÜTZ AUXILIARY CONTACTOR 14 498334601 VERRIEGELUNG MECHANISCH INTERLOCK, MECHANICAL 15 498334451 SCHÜTZ MOTORANLAUF 81 A CONTACTOR, NONREVERSING, 81 A 16 498334781 SATZ, KABEL Y/D KIT, WIRING Y/D 17 050956092 KABEL ERDUNG #6-#350 CABLE, GROUND LUG-COPPER, #6-#350 18 954236202 SCHRAUBE, SECHSKANT, 5/16-18 x 3/4 SCREW, HEX, 5/16-18 x 3/4 19 101701400,61 KABEL #6/10MM2, GRÜN/GELB WIRE, #6/10MM2, GREEN/YELLOW 20 101701571,07 KABEL #10/4MM2, GRÜN/GELB WIRE, #10/4MM2, GREEN/YELLOW 21 050198982,29 KABEL #14 SCHWARZ WIRE, #14, BLACK 22 0501961712 ADERENDHÜLSE #14/2.5 MM2 CRIMP, CONNECTOR, #14/2.5 MM2 23 051406861 SCHALTER SICHERUNG CIRCUIT BREAKER 24 050323627 HALTERUNG KLEMMLEISTE END ANCHOR, TERMINAL BLOCK 25 051402231 TRANSFORMATOR 220/380/415 VAC - 24 VDC POWER SUPPLY, 220/380/415 VAC - 24 VDC 26 051485151 UNTERBAUGRUPPE STEUERUNG SLIV 50-PLUS SUBASSEMBLY CONTROLS SLIV 50-PLUS 27 498334291 RELAIS ZEITVERZÖGERUNG RELAY, TIMING

April 2003 2. SCHALT-/STEUERSCHRANK <---> 2. STARTER/CONTROL PANEL 12 - 33 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5148564 2. SCHALT-/STEUERSCHRANK <---> 2. STARTER/CONTROL PANEL

Pos. CPN Qty. Bezeichnung Description 28 101853958 ADERENDHÜLSE #16 CRIMP, CONNECTOR, #16 29 101764101,22 LEITUNG VERDRAHTUNG BLAU WIRE #16 BLUE 30 101701651,22 LEITUNG VERDRAHTUNG GRÜN/GELB WIRE #16 GREEN/YELLOW

April 2003 2. SCHALT-/STEUERSCHRANK <---> 2. STARTER/CONTROL PANEL 12 - 34 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 5148515 3. BAUGRUPPE STEUERUNG <---> 3. ASSEMBLY CONTROLS

A

A

April 2003 3. BAUGRUPPE STEUERUNG <---> 3. ASSEMBLY CONTROLS 12 - 35 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5148515 3. BAUGRUPPE STEUERUNG <---> 3. ASSEMBLY CONTROLS

Pos. CPN Qty. Bezeichnung Description 03 050324203 KLEMMLEISTE IEC #22-#12 TERMINAL BLOCK, IEC #22-#12 04 101030340,92 ANSCHLUSSKLEMMLEISTE RAIL, DIN-STEEL 05 1015766712 SCHRAUBE, #10-32 x 3/4 SCREW, #10-32 x 3/4 06 051059941 SCHALTER SICHERUNG 10A/480V 1-POLIG CIRCUIT BREAKER, 10A/480V 1-POLE 07 498334031 SCHALTER NOTAUS, SLIV-PLUS SWITCH, EMERGENCY STOP, SLIV-PLUS 08 051406521 STEUERSCHÜTZ BLOCK, CONTACTOR 09 050494731 SCHILD NOT-AUS SCHALTER LEGEND PLATE, EMERGENCY STOP 10 0503243820 KLEMMLEISTE IEC #22-#14 TERMINAL BLOCK, IEC #22-#14 12 050323624 HALTERUNG KLEMMLEISTE END ANCHOR, TERMINAL BLOCK 13 050323701 ANSCHLUSSKAPPE IEC END BARRIER, IEC 14 050323881 BRÜCKE KLEMMLEISTE 5 MM JUMPER, TERMINAL BLOCK, 5 MM 15 051128181 SCHILDER KLEMMLEISTE, SLIV-50-PLUS MARKER, TERMINAL BLOCK, SLIV-50-PLUS 16 101861041 RELAIS 24 VDC 3 POLIG RELAY, 24 VDC, 3 POLE 17 101960121 GRUNDPLATTE RELAIS, 11 PINS BASE, RELAY, 11 PINS 18 498333951 SCHALTER, DRUCKKNOPF, WEISS SWITCH, PUSHBUTTON, WHITE 19 498334861 ANSCHLUSSBLOCK BLOCK CONTACT 21 498333791 DRUCKKNOPF GRÜN, SL-IV-PLUS PUSH BUTTON, GREEN 22 0511363414 KLEMMLEISTE BLOCK 18-12 GRAU 3x ERDE TERMINAL BLOCK, 18-12 GREY, 3x GROUND 23 051128261 KLEMMLEISTE BLOCK TERMINAL BLOCK 24 498302681 KABEL CABLE 26 050494321 HALTER SCHILDER SCHWARZ HOLDER, LEGEND PLATE, BLACK 28 051405041 GRUNDPLATTE, SL-IV 50-PLUS SUB-PLATE, SL-IV 50-PLUS 29 101568591 PLATINE OPTO-KOPPLER 4 SLOT SLIII RACK, OPTO-KOPPLER, 4 SLOT, SLIII 30 101463634 MODUL SIGNAL DRUCK/TEMPERATUR SLIII MODULE, SIGNAL P/T, 24VDC, SLIII 31 101576592 FEDERRING 1/4" WASHER, LOCK, 1/4" 32 050219441 KABELKANAL 1"x2"x6FEET PVC DUCT, WIRING, 1"x2"x6FEET, PVC 33 1017013233 KABELHÜLSEN NYLON 0.187" RIVET, NYLON, PUSH, 0.187"

April 2003 3. BAUGRUPPE STEUERUNG <---> 3. ASSEMBLY CONTROLS 12 - 36 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5148515 3. BAUGRUPPE STEUERUNG <---> 3. ASSEMBLY CONTROLS

Pos. CPN Qty. Bezeichnung Description 34 498741914 VERSCHLUSSKAPPE RUND KABELKANAL 1/2" SEAL, HOLE, CONDUIT, 1/2" 37 100698881 FEDERRING #6 WASHER, LOCK, #6 38 051400821 GEHAEUSE STEUERSCHRANK SL-IV 50PLUS ENCLOSURE, ELECTRICAL SL-IV 50-PLUS 39 051409671 DICHTUNG STECKER GASKET, CONNECTOR 40 101701570,91 KABEL #10/4MM2, GRÜN/GELB WIRE, #10/4MM2, GREEN/YELLOW 41 100947123 RING MOTORKLEMMBRETT 14-10 1/4" RING, TERMINAL BLOCK, 14-10 1/4" 42 954163354 MUTTER SECHSKANT 1/4"-20 NUT, HEX, 1/4"-20 43 498333871 LEUCHTE ROT 24 VDC LIGHT, PILOT, RED 24 VDC 44 051409751 KAPPE, STECKER CAP, CONNECTOR 45 101022420,31 SPIRALSCHLAUCH 3/8" POLY SPIRAL WRAP, 3/8", POLY 46 100982261 RELAIS RÖHRENBASIS 24VDC RELAY, TUBE BASE, 24VDC 47 100982421 HALTERUNG RELAIS RÖHRENBASIS SOCKET BASE, TUBE RELAIS 48 100697971 SCHEIBE, FLACH, #6 WASHER, FLAT, #6 49 051443161 SPS-STEUERUNG BASISEINHEIT SLIV CTRL-BASE, 1500, 24V 50 100709511 SCHRAUBE, SCHLITZKOPF, 6-32x3/4 SCREW, PAN HEAD, 6-32x3/4 51 051401571 ANZEIGE PANELVIEW 550 TOUCHSCREEN DISPLAY PANELVIEW 550 TOUCHSCREEN 52 051151341 ANSCHLUSSKAPPE WIDERSTAND END BARRIER 53 498334111 WAHLSCHALTER SWITCH, SELECTOR 54 051148891 SCHILD -FERNSTEUERUNG- PLATE -REMOTE CONTROL- 55 051176011 ANSCHLUSSKAPPE END BARRIER 56 101744311 STECKER WEIBLICH CONNECTOR, RECEPTACLE 57 101747121 STECKDOSE SOCKET, CONTACT 58 100699461 MUTTER, SECHSKANT, #6 NUT, HEX, #6 59 051157041 KLEMMLEISTE TERMINAL BLOCK 60 051443081 SPS-STEUERUNG SLIV 50 FD AB CONTROLLER PROGRAMM SLIV FD AB 61 498742331 VERSCHLUSSKAPPE SEAL, HOLE

April 2003 3. BAUGRUPPE STEUERUNG <---> 3. ASSEMBLY CONTROLS 12 - 37 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 51485491 4.1 SCHALTPLAN BLATT 1 <---> 4.1 ELECTRICAL SCHEMATIC SHEET 1

April 2003 4.1 SCHALTPLAN BLATT 1 <---> 4.1 ELECTRICAL SCHEMATIC SHEET 1 12 - 38 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 51485492 4.2 SCHALTPLAN BLATT 2 <---> 4.2 ELECTRICAL SCHEMATIC SHEET 2

April 2003 4.2 SCHALTPLAN BLATT 2 <---> 4.2 ELECTRICAL SCHEMATIC SHEET 2 12 - 39 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 51485493 4.3 SCHALTPLAN BLATT 3 <---> 4.3 ELECTRICAL SCHEMATIC SHEET 3

April 2003 4.3 SCHALTPLAN BLATT 3 <---> 4.3 ELECTRICAL SCHEMATIC SHEET 3 12 - 40 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 51485494 4.4 SCHALTPLAN BLATT 4 <---> 4.4 ELECTRICAL SCHEMATIC SHEET 4

April 2003 4.4 SCHALTPLAN BLATT 4 <---> 4.4 ELECTRICAL SCHEMATIC SHEET 4 12 - 41 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

E. ELEKTRISCHES SYSTEM / E. ELECTRICAL SYSTEM ZEICHNUNG VON / DRAWING OF CPN 51485495 4.5 SCHALTPLAN BLATT 5 <---> 4.5 ELECTRICAL SCHEMATIC SHEET 5

April 2003 4.5 SCHALTPLAN BLATT 5 <---> 4.5 ELECTRICAL SCHEMATIC SHEET 5 12 - 42 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5148762 1. UMBAUSATZ SLIV 50HP STD/PLUS (FD) -> RED <---> 1. KIT RETROFIT SLIV STD/PLUS (FD) -> RED

April 2003 1. UMBAUSATZ SLIV 50HP STD/PLUS (FD) -> RED <---> 1. KIT RETROFIT SLIV STD/PLUS (FD) -> RED 12 - 43 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5148762 1. UMBAUSATZ SLIV 50HP STD/PLUS (FD) -> RED <---> 1. KIT RETROFIT SLIV STD/PLUS (FD) -> RED

Pos. CPN Qty. Bezeichnung Description 01 051488611 HD-ROHR 3/8" GEBOGEN TUBE 3/8" BENT 02 051488531 HD-ROHR 3/8" GEBOGEN TUBE 3/8" BENT 03 100975331 VENTIL, 3-WEGE VALVE, 3-WAY 04 100781292 HD-MUTTER, ÜBERWURF, 3/8" NUT, GLAND, HP, 3/8" 05 100787152 HD-ROHRMUTTER, 3/8" COLLAR, HP, 3/8" 06 051442171 DRUCKÜBERSETZER KOMPLETT SLIV-PLUS TOPWORKS, INTENSIFIER, SLIV-PLUS 07 954136964 FEDERRING 1/2"x0.125" WASHER, LOCK, 1/2"x0.125" 08 953837904 SCHRAUBE INNENSECHSKANT 1/2"x1" SCREW, SOCKET HEAD, 1/2"x1" 09 101861532,16 SCHLAUCH SCHUTZ HD-ROHR 1/4"&3/8" CONDUIT, PROTECTION, HP TUBE 1/4"&3/8" 10 101054431 HD-NIPPELROHR 3/8" L=101,6MM HP-NIPPLE TUBE, 3/8" L=4" 11 051486552 HD-ROHR 3/8" GEBOGEN, 3/8" x 4 TUBE 3/8" BENT, 3/8" x 4 12 1008389710 ENDRING, ROHRSCHUTZ FERRULE, 1/4" 13 498953032 ADAPTER GERADE 1/2" NPT X -8 JIC V2A ADAPTER, STRAIGHT, 1/2" NPT X -8 JIC SS 14 050711052 SCHLAUCH HD-HYDRAULIK 3/4" L=1016 mm HOSE ASSY, HP HYDRAULIC, 3/4" L=1016 mm 15 050731502 ADAPTER JIC/O-RING GERADE 10-12 ADAPTER, JIC/O-RING, STRAIGHT 10-12 16 050731762 ADAPTER O-RING MOD 05073143 ADAPTER, O-RING, MOD 05073143 17 050707504 VENTIL KUGEL 2-WEGE 3/4" VALVE, BALL, 2-WAY, 3/4" 18 050575424 ADAPTER O-RING/O-RING GERADE 12 ADAPTER, O-RING/O-RING, STRAIGHT 12 19 050731684 KUPPLUNG 45° JIC/O-RING 3/4"x3/4" COUPLING, 45° JIC/O-RING, 3/4"x3/4" 20 100841842 STECKER WEIBLICH 3-2M CONNECTOR, PLUG, FEMALE, 3-2M 21 100672052 KABEL STECKER 1/2" CABLE, CONNECTOR, 1/2" 22 100830122 MUTTER SICHERUNG 1/2" NUT, LOCK, 1/2" 23 100828572 DICHTUNG FLEXIBLE 1/2" GASKET ASSY, FLEXIBLE, 1/2"

April 2003 1. UMBAUSATZ SLIV 50HP STD/PLUS (FD) -> RED <---> 1. KIT RETROFIT SLIV STD/PLUS (FD) -> RED 12 - 44 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5144803 2. BAUSATZ ZWEITER DRUCKSPEICHER SL-IV PLUS <---> 2. KIT SECOND ACCUMUALTOR SL-IV PLUS

April 2003 2. BAUSATZ ZWEITER DRUCKSPEICHER SL-IV PLUS <---> 2. KIT SECOND ACCUMUALTOR SL-IV PLUS 12 - 45 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 5144803 2. BAUSATZ ZWEITER DRUCKSPEICHER SL-IV PLUS <---> 2. KIT SECOND ACCUMUALTOR SL-IV PLUS

Pos. CPN Qty. Bezeichnung Description 01 051488041 HALTERUNG, DRUCKSPEICHER, SL-IVPLUS SUPPORT, ACCUMULATOR, SL-IVPLUS 02 050406961 DRUCKSPEICHER TÜV 1 LITER SLIV ACCUMULATOR, TUV, 1 LITER, SLIV 03 050919548 SCHRAUBE RUNDKOPF 3/8"x1" SCREW, BUTTON HEAD, 3/8"x1" 04 956709728 FEDERRING 0.36"x0.094" WASHER, RING, 0.36"x0.094" 05 956609578 SCHEIBE FLACH 3/8"x0.078" WASHER, FLAT, 3/8"x0.078" 06 100794652 KUPPLUNG HOCHDRUCK T-STÜCK 9/16" COUPLING, HP, TEE, 9/16" 07 051120572 HD-NIPPELROHR 9/16" L = 126 MM HP-NIPPLE 9/16" L = 4.97 " 08 050907172 MUTTER GEHÄUSE DRUCKSPEICHER SLIV NUT, HOUSING, ACCUMULATOR, SLIV

April 2003 2. BAUSATZ ZWEITER DRUCKSPEICHER SL-IV PLUS <---> 2. KIT SECOND ACCUMUALTOR SL-IV PLUS 12 - 46 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 80195 3. UMBAUSATZ ÖL/LUFTKÜHLUNG <---> 3. KIT RETROFIT OIL/AIR COOLER

April 2003 3. UMBAUSATZ ÖL/LUFTKÜHLUNG <---> 3. KIT RETROFIT OIL/AIR COOLER 12 - 47 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

STÜCKLISTE FÜR / BILL OF MATERIAL FOR CPN 80195 3. UMBAUSATZ ÖL/LUFTKÜHLUNG <---> 3. KIT RETROFIT OIL/AIR COOLER

Pos. CPN Qty. Bezeichnung Description 01 000801971 ÖL/LUFTKÜHLER SL-IV 30/50HP OIL/AIR COOLER, SL-IV 30/50HP 02 000801981 FÜHLER TEMPERATUR ÖL/LUFTKÜHLER SENSOR, TEMPERATURE, OIL/AIR COOLER 03 050497131 SCHLAUCH ND-HYDRAULIK 3/4" WEIBLICH HOSE ASSY, LP HYDRAULIC, 3/4" FEMALE 04 050857412 VERSCHRAUBUNG SCHOTT 1/2" NPT COUPLING, BULKHEAD, 1/2" NPT 05 050711051 SCHLAUCH HD-HYDRAULIK 3/4" L=1016 mm HOSE ASSY, HP HYDRAULIC, 3/4" L=1016 mm 06 050699762 STOPFEN VERSCHLUSS ÖLBEFÜLLUNG SLIV PLUG, HEX, OIL FILL PORT, SLIV 07 100672053 KABEL STECKER 1/2" CABLE, CONNECTOR, 1/2" 08 100830123 MUTTER SICHERUNG 1/2" NUT, LOCK, 1/2" 09 050496551 KUPPLUNG 90° ROHR/JIC 16x12 COUPLING, 90°, PIPE/JIC, 16x12 10 100878231 KUPPLUNG 45° ROHR/JIC 12x12 COUPLING, 45°, PIPE/JIC, 12x12 11 100879891 KUPPLUNG GERADE ROHR/JIC 12x12 COUPLING, STRAIGHT, PIPE/JIC, 12x12 12 101001881 KUPPLUNG GERADE ROHR/JIC 16x12 COUPLING, STRAIGHT, PIPE/JIC, 16x12 13 000802032 SCHRAUBE SECHSKANT M4X25 MM SCREW, HEX HEAD, M4X25 MM 14 000802043,3 STEUERLEITUNG ÖZ-J 3X0.75 qmm CABLE, CONTROL, ÖZ-J 3X0.75 qmm 15 000802055 STEUERLEITUNG ÖZ-J 4X0.75 qmm CABLE, CONTROL, ÖZ-J 4X0.75 qmm 16 000802061 KLEMME ERDUNG CLAMP GROUND 17 000802071 KABEL GELB/GRÜN 1.5 qmm CABLE YELLOW/GREEN 1.5 qmm 18 000802081 KABEL BLAU 0.75 qmm CABLE BLUE 0.75 qmm 19 000802091 KABEL SCHWARZ 2.5 qmm CABLE BLACK 2.5 qmm 20 000802101 SCHALTER MOTORSCHUTZ 24VDC-1.6 A CIRCUIT BREAKER, MOTOR, 24VDC-1.6 A 21 000802111 SCHALTER ZUSATZ MOTORSCHUTZ CIRCUIT BREAKER, AUXILIARY, MOTOR

April 2003 3. UMBAUSATZ ÖL/LUFTKÜHLUNG <---> 3. KIT RETROFIT OIL/AIR COOLER 12 - 48 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5066292 3.1 SCHALTPLAN BLATT 1 <---> 3.1 ELECTRICAL SCHEMATIC SHEET 1

April 2003 3.1 SCHALTPLAN BLATT 1 <---> 3.1 ELECTRICAL SCHEMATIC SHEET 1 12 - 49 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5066293 3.2 SCHALTPLAN BLATT 2 <---> 3.2 ELECTRICAL SCHEMATIC SHEET 2

April 2003 3.2 SCHALTPLAN BLATT 2 <---> 3.2 ELECTRICAL SCHEMATIC SHEET 2 12 - 50 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5066294 3.3 SCHALTPLAN BLATT 3 <---> 3.3 ELECTRICAL SCHEMATIC SHEET 3

April 2003 3.3 SCHALTPLAN BLATT 3 <---> 3.3 ELECTRICAL SCHEMATIC SHEET 3 12 - 51 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5066295 3.4 SCHALTPLAN BLATT 4 <---> 3.4 ELECTRICAL SCHEMATIC SHEET 4

April 2003 3.4 SCHALTPLAN BLATT 4 <---> 3.4 ELECTRICAL SCHEMATIC SHEET 4 12 - 52 ERSATZTEILLISTE / SPARE PARTS LISTS STREAMLINE SL-IV 50HP - STD/PLUS

F. OPTIONEN / E. OPTIONS ZEICHNUNG VON / DRAWING OF CPN 5066296 3.5 SCHALTPLAN BLATT 5 <---> 3.5 ELECTRICAL SCHEMATIC SHEET 5

April 2003 3.5 SCHALTPLAN BLATT 5 <---> 3.5 ELECTRICAL SCHEMATIC SHEET 5 12 - 53